CN114423721A - 混凝土构件及其生产方法 - Google Patents
混凝土构件及其生产方法 Download PDFInfo
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- CN114423721A CN114423721A CN202080064396.XA CN202080064396A CN114423721A CN 114423721 A CN114423721 A CN 114423721A CN 202080064396 A CN202080064396 A CN 202080064396A CN 114423721 A CN114423721 A CN 114423721A
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- Prior art keywords
- concrete
- mixture
- concrete element
- binder
- element according
- Prior art date
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- Pending
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- 239000004567 concrete Substances 0.000 title claims abstract description 185
- 238000004519 manufacturing process Methods 0.000 title description 11
- 239000000203 mixture Substances 0.000 claims abstract description 140
- 239000011230 binding agent Substances 0.000 claims abstract description 86
- 239000008187 granular material Substances 0.000 claims abstract description 69
- 239000004848 polyfunctional curative Substances 0.000 claims abstract description 22
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 19
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 42
- 239000002245 particle Substances 0.000 claims description 29
- 238000000034 method Methods 0.000 claims description 26
- 239000002893 slag Substances 0.000 claims description 25
- 239000000945 filler Substances 0.000 claims description 23
- 239000000463 material Substances 0.000 claims description 22
- 239000004576 sand Substances 0.000 claims description 17
- 239000000049 pigment Substances 0.000 claims description 15
- 238000007873 sieving Methods 0.000 claims description 13
- 239000000654 additive Substances 0.000 claims description 12
- 239000004568 cement Substances 0.000 claims description 11
- 239000010881 fly ash Substances 0.000 claims description 11
- 239000004575 stone Substances 0.000 claims description 11
- 239000003795 chemical substances by application Substances 0.000 claims description 10
- 238000010410 dusting Methods 0.000 claims description 9
- 239000000843 powder Substances 0.000 claims description 9
- 239000000377 silicon dioxide Substances 0.000 claims description 9
- 239000011236 particulate material Substances 0.000 claims description 8
- 235000019353 potassium silicate Nutrition 0.000 claims description 8
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 8
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims description 7
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 7
- 238000005056 compaction Methods 0.000 claims description 6
- 239000011521 glass Substances 0.000 claims description 6
- 238000012216 screening Methods 0.000 claims description 6
- -1 alkali metal aluminates Chemical class 0.000 claims description 5
- 150000008044 alkali metal hydroxides Chemical class 0.000 claims description 5
- 239000000428 dust Substances 0.000 claims description 5
- 235000019738 Limestone Nutrition 0.000 claims description 4
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical class O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 4
- 239000006028 limestone Substances 0.000 claims description 4
- 239000004033 plastic Substances 0.000 claims description 4
- 229920003023 plastic Polymers 0.000 claims description 4
- 239000011435 rock Substances 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 239000005909 Kieselgur Substances 0.000 claims description 3
- 229910000288 alkali metal carbonate Inorganic materials 0.000 claims description 3
- 150000008041 alkali metal carbonates Chemical class 0.000 claims description 3
- 229910000272 alkali metal oxide Inorganic materials 0.000 claims description 3
- 239000003054 catalyst Substances 0.000 claims description 3
- SHFGJEQAOUMGJM-UHFFFAOYSA-N dialuminum dipotassium disodium dioxosilane iron(3+) oxocalcium oxomagnesium oxygen(2-) Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Na+].[Na+].[Al+3].[Al+3].[K+].[K+].[Fe+3].[Fe+3].O=[Mg].O=[Ca].O=[Si]=O SHFGJEQAOUMGJM-UHFFFAOYSA-N 0.000 claims description 3
- 229910021485 fumed silica Inorganic materials 0.000 claims description 3
- 239000010437 gem Substances 0.000 claims description 3
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 239000010445 mica Substances 0.000 claims description 3
- 229910052618 mica group Inorganic materials 0.000 claims description 3
- 239000010451 perlite Substances 0.000 claims description 3
- 235000019362 perlite Nutrition 0.000 claims description 3
- 229910021487 silica fume Inorganic materials 0.000 claims description 3
- 239000010455 vermiculite Substances 0.000 claims description 3
- 229910052902 vermiculite Inorganic materials 0.000 claims description 3
- 235000019354 vermiculite Nutrition 0.000 claims description 3
- 239000004925 Acrylic resin Substances 0.000 claims description 2
- 229910052783 alkali metal Inorganic materials 0.000 claims description 2
- 229920000180 alkyd Polymers 0.000 claims description 2
- 230000001680 brushing effect Effects 0.000 claims description 2
- 239000003245 coal Substances 0.000 claims description 2
- 239000008139 complexing agent Substances 0.000 claims description 2
- 239000002270 dispersing agent Substances 0.000 claims description 2
- 239000006185 dispersion Substances 0.000 claims description 2
- 239000000839 emulsion Substances 0.000 claims description 2
- 239000003822 epoxy resin Substances 0.000 claims description 2
- 239000000835 fiber Substances 0.000 claims description 2
- 238000000227 grinding Methods 0.000 claims description 2
- 239000010440 gypsum Substances 0.000 claims description 2
- 229910052602 gypsum Inorganic materials 0.000 claims description 2
- 239000004572 hydraulic lime Substances 0.000 claims description 2
- 229910052907 leucite Inorganic materials 0.000 claims description 2
- 239000003077 lignite Substances 0.000 claims description 2
- 239000004014 plasticizer Substances 0.000 claims description 2
- 229920000647 polyepoxide Polymers 0.000 claims description 2
- 239000004814 polyurethane Substances 0.000 claims description 2
- 229920002635 polyurethane Polymers 0.000 claims description 2
- 238000002360 preparation method Methods 0.000 claims description 2
- 239000008262 pumice Substances 0.000 claims description 2
- 239000011347 resin Substances 0.000 claims description 2
- 229920005989 resin Polymers 0.000 claims description 2
- 239000006254 rheological additive Substances 0.000 claims description 2
- 238000005488 sandblasting Methods 0.000 claims description 2
- 229920002050 silicone resin Polymers 0.000 claims description 2
- 239000000080 wetting agent Substances 0.000 claims description 2
- 229920000426 Microplastic Polymers 0.000 claims 1
- 239000002956 ash Substances 0.000 claims 1
- 239000000565 sealant Substances 0.000 claims 1
- 239000010410 layer Substances 0.000 description 33
- 239000000853 adhesive Substances 0.000 description 15
- 230000001070 adhesive effect Effects 0.000 description 15
- 238000002156 mixing Methods 0.000 description 9
- 238000003825 pressing Methods 0.000 description 6
- 230000000996 additive effect Effects 0.000 description 5
- 229910052681 coesite Inorganic materials 0.000 description 5
- 229910052906 cristobalite Inorganic materials 0.000 description 5
- 238000011049 filling Methods 0.000 description 5
- 229910052682 stishovite Inorganic materials 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 229910052905 tridymite Inorganic materials 0.000 description 5
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 239000002585 base Substances 0.000 description 4
- 239000004566 building material Substances 0.000 description 4
- 235000013312 flour Nutrition 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 235000012239 silicon dioxide Nutrition 0.000 description 4
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 3
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 235000011941 Tilia x europaea Nutrition 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 229910002092 carbon dioxide Inorganic materials 0.000 description 3
- 229910052593 corundum Inorganic materials 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 239000004571 lime Substances 0.000 description 3
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- 239000011734 sodium Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 description 3
- 239000005995 Aluminium silicate Substances 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- WMFOQBRAJBCJND-UHFFFAOYSA-M Lithium hydroxide Chemical compound [Li+].[OH-] WMFOQBRAJBCJND-UHFFFAOYSA-M 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- 241000519995 Stachys sylvatica Species 0.000 description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 description 2
- 235000012211 aluminium silicate Nutrition 0.000 description 2
- 229910021486 amorphous silicon dioxide Inorganic materials 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 238000002845 discoloration Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000006253 efflorescence Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000004570 mortar (masonry) Substances 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 229910052700 potassium Inorganic materials 0.000 description 2
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Chemical compound [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 2
- 206010037844 rash Diseases 0.000 description 2
- 230000009257 reactivity Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- VXEGSRKPIUDPQT-UHFFFAOYSA-N 4-[4-(4-methoxyphenyl)piperazin-1-yl]aniline Chemical compound C1=CC(OC)=CC=C1N1CCN(C=2C=CC(N)=CC=2)CC1 VXEGSRKPIUDPQT-UHFFFAOYSA-N 0.000 description 1
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- 239000010754 BS 2869 Class F Substances 0.000 description 1
- 239000005046 Chlorosilane Substances 0.000 description 1
- 229910000519 Ferrosilicon Inorganic materials 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- FUJCRWPEOMXPAD-UHFFFAOYSA-N Li2O Inorganic materials [Li+].[Li+].[O-2] FUJCRWPEOMXPAD-UHFFFAOYSA-N 0.000 description 1
- 229910003202 NH4 Inorganic materials 0.000 description 1
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 229910001413 alkali metal ion Inorganic materials 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- KOPOQZFJUQMUML-UHFFFAOYSA-N chlorosilane Chemical class Cl[SiH3] KOPOQZFJUQMUML-UHFFFAOYSA-N 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- XUCJHNOBJLKZNU-UHFFFAOYSA-M dilithium;hydroxide Chemical group [Li+].[Li+].[OH-] XUCJHNOBJLKZNU-UHFFFAOYSA-M 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000005562 fading Methods 0.000 description 1
- 150000004673 fluoride salts Chemical class 0.000 description 1
- 238000009415 formwork Methods 0.000 description 1
- 239000000499 gel Substances 0.000 description 1
- 229920000876 geopolymer Polymers 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 229910052808 lithium carbonate Inorganic materials 0.000 description 1
- XGZVUEUWXADBQD-UHFFFAOYSA-L lithium carbonate Chemical group [Li+].[Li+].[O-]C([O-])=O XGZVUEUWXADBQD-UHFFFAOYSA-L 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 229910000027 potassium carbonate Inorganic materials 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 230000001698 pyrogenic effect Effects 0.000 description 1
- 239000011378 shotcrete Substances 0.000 description 1
- 229910002027 silica gel Inorganic materials 0.000 description 1
- 239000000741 silica gel Substances 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000005049 silicon tetrachloride Substances 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- RLQWHDODQVOVKU-UHFFFAOYSA-N tetrapotassium;silicate Chemical compound [K+].[K+].[K+].[K+].[O-][Si]([O-])([O-])[O-] RLQWHDODQVOVKU-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
- B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
- B28B13/022—Feeding several successive layers, optionally of different 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
- 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
-
- 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
- B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
-
- 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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
- B28B11/0818—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for roughening, profiling, corrugating
-
- 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
- C04B12/00—Cements not provided for in groups C04B7/00 - C04B11/00
- C04B12/04—Alkali metal or ammonium silicate cements ; Alkyl silicate cements; Silica sol cements; Soluble silicate cements
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/047—Zeolites
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/06—Quartz; Sand
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/06—Quartz; Sand
- C04B14/062—Microsilica, e.g. colloïdal silica
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/06—Quartz; Sand
- C04B14/064—Silica aerogel
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/06—Quartz; Sand
- C04B14/066—Precipitated or pyrogenic silica
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/08—Diatomaceous earth
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/10—Clay
-
- 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
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Abstract
本发明涉及包括核心混凝土层和饰面混凝土层的混凝土构件，其中该饰面混凝土层通过压实和硬化包含潜在水硬性粘合剂和/或凝硬性粘合剂、水、粒状材料和碱性硬化剂的混合物得到，其中粒状材料在2mm的筛孔宽度下具有35.5重量％至99.5重量％的过筛量，并且在0.25mm的筛孔宽度下具有2.5重量％至33.5重量％的过筛量，分别基于粒状材料的总重量。
Description
技术领域
本发明涉及一种混凝土构件，其包括核心混凝土层和饰面混凝土层，其中该饰面混凝土层通过压实和硬化包含潜在水硬性粘合剂和/或凝硬性粘合剂、水、粒状材料和碱性硬化剂的混合物得到。本发明还涉及一种用于生产根据本发明的混凝土构件的方法。
背景技术
与由天然石头制成的砖材、板材或台阶相比，混凝土构件，例如混凝土块、混凝土板、混凝土墙构件或混凝土台阶由于其耐用性和较低的价格而经常被使用。混凝土构件通常通过使用水泥作为粘合剂来生产。
在此，已经开发了各种方法来使混凝土构件具有装饰性外观。为此，通常添加颜料和/或天然石掺和物和/或沙子以对混凝土构件提供颜色。
含水泥的混凝土构件有时会具有随着时间的推移在表面上形成白色斑点的问题。此外染色的混凝土块的颜色也可能褪色。这两种影响似乎都是由石灰的形成引起的。表面上的白色斑点归因于石灰风化，石灰风化是由运输到表面的氢氧化钙与二氧化碳反应形成的。据推测，褪色是由于沉降在水泥颗粒上以提供颜色的颜料慢慢地被形成的碳酸钙涂覆而引起的。由此，颜料的色彩外观慢慢消失。
作为水泥的替代品的粘合剂是已知的。这种替代粘合剂的一个例子是基于化学结构单元SiO2与Al2O3的组合。这种粘合剂的例子是潜在水硬性粘合剂和凝硬性粘合剂。其通常被称为“地质聚合物”。EP 1 236 702 A1例如说明了一种包含水玻璃和潜在水硬性粘合剂的建筑材料混合物。EP 1 236 702 A1建议使用建筑材料混合物作为砂浆或填料。
EP 1 081 114 A1还说明了一种用于生产耐化学物质的砂浆的建筑材料混合物，其中该建筑材料混合物包含水玻璃粉末、至少一种水玻璃硬化剂、无机填料和至少10重量％的潜在水硬性粘合剂。
WO 2014/067721 A1公开了一种由碱性物质活化的硅铝酸盐粘合剂。根据WO2014/067721 A1，硅铝酸盐粘合剂适用于新拌混凝土、混凝土部件、喷射混凝土、建筑胶粘剂和其他应用。
混凝土构件，例如混凝土块、混凝土板、混凝土墙构件或混凝土台阶的生产对所使用的混凝土混合物提出了特殊要求，尤其是与新鲜混凝土相比时。在生产混凝土构件时，希望在尽可能短的时间后使尚未硬化的混凝土块达到尽可能高的稳定性，以便尽快包装。对包含饰面混凝土层和核心混凝土的产品的附加要求是高粘合强度，以防止饰面混凝土层在负载下从核心分层剥离。附着抗拉强度可用作混凝土构件的饰面混凝土层抵抗与核心混凝土分层的稳定性的度量。如果混凝土构件的附着抗拉强度不够高，则饰面混凝土层和核心混凝土会在荷载作用下分离(分层)或在拆除模板时就已撕裂。因此，如果混凝土构件以足够高的附着抗拉强度调配，则可以用更短的周期时间生产混凝土构件，并因此更经济。
在本发明的开发过程中，发现含有潜在水硬性粘合剂和/或凝硬性粘合剂作为粘合剂的混凝土构件或混凝土构件层在其他情况类似的生产条件和组分下与含有水泥作为粘合剂的混凝土构件相比具有更小的附着抗拉强度。
发明内容
因此，本发明的目的是提供美学上高要求的混凝土构件，随着时间的推移其外观并不强烈变化并且可以经济地生产。尤其应提供在表面上较难形成斑点和/或发生污染和/或较少褪色和/或具有足够高的附着抗拉强度的混凝土块。本发明的另一个目的是提供具有减少的CO2平衡的混凝土构件。
进一步的目的在下面的实施方案中给出，并部分在此后示出。
根据本发明，利用根据权利要求1的混凝土构件和根据权利要求17的方法解决了这些目的中的所有或部分。
本发明的有利实施例在从属权利要求中给出并且在下文中详细解释。
本发明提供了一种混凝土构件，包括核心混凝土层和饰面混凝土层，其中该饰面混凝土层通过压实和硬化包含潜在水硬性粘合剂和/或凝硬性粘合剂、水、粒状材料和碱性硬化剂的混合物得到，其中粒状材料在2mm的筛孔宽度下具有35.5重量％至99.5重量％的过筛量，并且在0.25mm的筛孔宽度下具有2.5重量％至33.5重量％的过筛量，分别基于粒状材料的总重量。
令人惊讶地发现，如果混凝土构件包括核心混凝土层和饰面混凝土层，其中该饰面混凝土层通过压实和硬化包含潜在水硬性粘合剂和/或凝硬性粘合剂、水、粒状材料和碱性硬化剂的混合物得到，其中粒状材料在2mm的筛孔宽度下具有35.5重量％至99.5重量％的过筛量，并且在0.25mm的筛孔宽度下具有2.5重量％至33.5重量％的过筛量，分别基于粒状材料的总重量，则其装饰性能即使发生变化，也非常缓慢，并且可以以具有成本效益的方式生产。上述混凝土构件尤其具有足够高的附着抗拉强度。这使得可以快速将它们从模具中取出，而不会撕裂未硬化的混凝土块。此外，这些混凝土块最多显示出颜色的缓慢褪色并且表面上几乎不形成或很少形成斑点。
不受任何特定科学理论的束缚，这似乎是由于潜在水硬性粘合剂和/或凝硬性粘合剂的存在导致混凝土块不会失去其装饰性能或可能只是缓慢地失去装饰性能。这似乎是因为根据本发明的混凝土构件比通常含有大量水泥的混凝土构件含有更少的CaO。还发现，在使用2mm筛孔宽度下具有35.5重量％至99.5重量％的过筛量并且0.25mm筛孔宽度下具有2.5重量％到33.5重量％的过筛量的粒状材料并且在使用潜在水硬性粘合剂和/或凝硬性粘合剂时，可以实现良好的附着拉伸强度。虽可以用较大直径的粒状材料生产混凝土构件，但其附着抗拉强度较差。不受任何科学理论的束缚，附着抗拉强度改进的原因可能是具有相当小的直径的粒状材料的组分具有更小的彼此之间的平均距离。这意味着可能较短的潜在水硬性粘合剂和/或凝硬性粘合剂链也可以将粒状材料的组分相互连接，从而改善尚未硬化的混凝土构件的机械性能，尤其是附着抗拉强度。
粒状材料也可以称为混凝土骨料。
尚未硬化的混凝土构件也可以称为生混凝土构件。
可以在具有一定测试年龄(例如56天)的混凝土块上确定附着抗拉强度。根据本发明的混凝土构件优选具有1MPa或更高的附着抗拉强度。
优选地，粒状材料在2mm的筛孔宽度下具有42.5重量％至99.5重量％、更优选56.5重量％至98.5重量％、特别优选72.5重量％至97.5重量％的过筛量，并且在0.25mm的筛孔宽度下具有2.5重量％至27.5重量％，更优选2.5重量％至22.5重量％，甚至更优选2.5重量％至21.5重量％，特别优选2.5重量％至8重量％或11.5重量％至21.5重量％的过筛量，基于粒状材料的总重量。已经发现，具有在所述筛孔宽度下的上述过筛量的粒状材料可以产生具有良好附着抗拉强度的混凝土构件。
上述两种筛孔宽度下的过筛量可以根据需要相互组合。
粒状材料还可以具有1.59至3.62、优选1.61至3.17、特别优选1.61至2.55的粒度模数。
粒状材料优选具有分级的颗粒组成。分级颗粒组成尤其包括具有不同颗粒尺寸的组分。
粒状材料可以以不同的量包含在混合物中。基于混合物的总重量，混合物中优选含有55重量％至80重量％，优选60重量％至75重量％，更优选60重量％至72重量％的粒状材料。基于混合物的总重量，该混合物可以特别优选含有60重量％至65重量％，尤其是60重量％至64重量％的粒状材料。基于混合物的总重量，混合物还可以特别优选含有67重量％至72重量％的粒状材料。
除了上述成分之外，混合物还可以包含其他成分，例如填料。基于混合物的总重量，该混合物优选含有1重量％至30重量％，优选1重量％至20重量％，更优选5重量％至18重量％，甚至更优选5重量％至15重量％，甚至更优选5重量％至10重量％，特别优选6重量％至8重量％的填料。
填料优选在0.025mm的筛孔宽度下具有63重量％至99重量％，优选68重量％至99重量％，更优选90重量％至99重量％，特别优选95重量％至99重量％的过筛量，并且在筛孔宽度为0.015mm时具有38重量％至73重量％，优选58重量％至67重量％，特别优选61重量％至66重量％的过筛量，基于填料的总重量。如果填料基于填料的总重量，在0.025mm的筛孔宽度下具有68重量％至77重量％的过筛量，并且在0.015mm的筛孔宽度下具有38重量％至47重量％的过筛量，则也可以获得良好的结果。
上述两种筛孔宽度下的过筛量可以根据需要相互组合。
已经发现，通过使用在所述筛孔宽度下具有上面列出的过筛量的填料可以进一步提高附着抗拉强度，尤其是尚未硬化的混凝土构件的附着抗拉强度。尤其是通过结合使用分别具有在上述筛孔宽度下的所述过筛量的粒状材料和填料，在附着抗拉强度方面可以实现最佳结果。由此也可以调整混合物，以使混凝土构件的装饰性能不变或变化很小。
多种材料可以用作填料。填料优选选自飞灰、矿渣砂、岩粉，优选分级岩粉、石灰石粉，优选分级石灰石粉、及其混合物。填料更优选为飞灰或矿渣砂。
使用上述填料可以经济地生产装饰性混凝土构件，其装饰性能不会褪去或只会缓慢褪去。
潜在水硬性粘合剂和/或凝硬性粘合剂可以以不同量包含在混合物中。该混合物优选含有15重量％至40重量％，优选20重量％至30重量％，更优选20重量％至24重量％，特别优选22重量％至24重量％的潜在水硬性粘合剂和/或凝硬性粘合剂，基于混合物的总重量。如果混合物基于混合物总重量包含26重量％至29重量％的潜在水硬性粘合剂和/或凝硬性粘合剂，也可以获得良好的结果。
相应地，基于混合物的总重量，混合物也可以仅含有15重量％至40重量％，优选20重量％至30重量％，更优选20重量％至24重量％或26重量％至29重量％，特别优选22重量％至24重量％的潜在水硬性粘合剂并且没有凝硬性粘合剂。基于混合物的总重量，该混合物也可以仅含有15重量％至40重量％，优选20重量％至30重量％，更优选20重量％至24重量％或26重量％至29重量％，特别优选22重量％至24重量％的凝硬性粘合剂并且没有潜在水硬性粘合剂。
已经发现，当使用低于15重量％的潜在水硬性粘合剂和/或凝硬性粘合剂时，所得混凝土构件不具有足够的强度。相反，使用超过40重量％的潜在水硬性粘合剂和/或凝硬性粘合剂是不经济的。
多种材料可用作潜在水硬性粘合剂。潜在水硬性粘合剂中的(CaO+MgO)∶SiO2的摩尔比优选为0.8至2.5，更优选为1.0至2.0。(CaO+MgO):SiO2摩尔比在上述范围内的潜在水硬性粘合剂可以很好地硬化。
潜在水硬性粘合剂有利地选自残渣、高炉炉渣，优选矿渣砂，尤其是磨碎的矿渣砂、电热磷矿渣、钢渣及其混合物。潜在水硬性粘合剂更优选为矿渣砂，特别是磨碎的矿渣砂。
残渣可以是工业残渣，即工业过程中的废品，也可以是合成产生的渣。后者是优选的，因为工业残渣并不总是以恒定的数量和等级获得。高炉炉渣，尤其是矿渣砂，是残渣的一个例子。
磨碎的矿渣砂的细度和粒度分布根据其来源和处理类型而有所不同。细度对反应性有影响。Blaine值尤其可以用作细度的度量。磨碎的矿渣砂的Blaine值优选为200至1000m2kg-1，更优选为450至650m2kg-1。
电热磷渣是电热磷生产过程中产生的废品。电热磷渣具有比高炉炉渣低的反应性并且含有约45至50重量％的CaO、约0.5至3重量％的MgO、约38至43重量％的SiO2、约2至5重量％的Al2O3和约0.2至3重量％的Fe2O3以及氟化物和磷酸盐。
钢渣是钢铁生产中的废品，其成分差异很大。
特别优选地，潜在水硬性粘合剂中(CaO+MgO):SiO2的摩尔比为0.8至2.5，潜在水硬性粘合剂选自上述材料。
多种材料可以用作凝硬性粘合剂。凝硬性粘合剂优选选自无定形二氧化硅、沉淀二氧化硅、热解二氧化硅、微硅粉、玻璃粉末、飞灰，如褐煤粉煤灰或硬煤粉煤灰、偏高岭土、天然白榴火山灰，如凝灰岩、浮石凝灰岩或火山灰、天然和合成的沸石、及其混合物。凝硬性粘合剂特别优选为无定形二氧化硅。
无定形二氧化硅优选在粉末衍射图中不显示结晶度。玻璃粉末优选也被认为是无定形二氧化硅。无定形二氧化硅有利地具有至少80重量％，优选至少90重量％的SiO2含量。优选地，沉淀二氧化硅在工业上通过沉淀水玻璃获得。根据生产的类型，沉淀二氧化硅也可以称为硅胶。热解二氧化硅是通过氯硅烷，如四氯化硅在氢氧焰中反应产生的。热解二氧化硅是无定形SiO2粉末，粒径为5至50nm，比表面积为50至600m2g-1。
微硅粉是硅或硅铁生产的副产品，并含有大量无定形SiO2粉末。颗粒的直径约为0.1μm。比表面积范围为15至30m2g-1。
飞灰例如是在燃煤发电厂中的燃烧过程中形成的。根据WO 2008/012438 A2，F级飞灰含有少于8重量％，优选少于5重量％的CaO。
偏高岭土由高岭土脱水而成。高岭土在100至200℃的温度范围内释放物理结合的水，而晶格结构的分解和偏高岭土(Al2Si2O7)的形成发生在500至800℃的范围内。纯偏高岭土优选包含约54重量％的SiO2和约46重量％的Al2O3。
已经发现，利用上述潜在水硬性粘合剂和凝硬性粘合剂可生产装饰性能不褪去或非常缓慢褪去的混凝土构件。
不同的材料可用作碱性硬化剂。碱性硬化剂优选选自碱金属氧化物、碱金属氢氧化物、碱金属碳酸盐、碱金属硅酸盐、碱金属铝酸盐及其混合物。碱性硬化剂更优选选自碱金属氢氧化物、碱金属硅酸盐及其混合物。
碱金属氧化物的实例是Li2O、Na2O、K2O、(NH4)2O及其混合物。碱金属氢氧化物的实例是LiOH、NaOH、KOH、NH4OH及其混合物。碱金属碳酸盐的实例是Li2CO3、Na2CO3、K2CO3、(NH4)2CO3及其混合物。由于与碱金属离子相似，因此也列出了铵离子。
碱金属硅酸盐有利地选自具有经验式mSiO2·nM2O的化合物，其中M是Li、Na、K或NH4或其混合物，优选Na或K。m:n的摩尔比范围为0.5至3.6，优选0.6至3.0，特别优选0.7至2.0。水玻璃，尤其是液态水玻璃，更优选液态钠水玻璃和/或钾水玻璃，已被证明是特别合适的碱金属硅酸盐。硅酸，尤其是水性硅酸，是另一种合适的碱金属硅酸盐。
上述碱性硬化剂优选以水溶液形式使用。这使进料更容易。
根据本发明的混凝土构件，尤其是饰面混凝土层的硬化可以容易地用上述碱性硬化剂调节。此外，这些碱性硬化剂与混合物中的其他组分表现出良好的相容性。
碱性硬化剂可以不同的量包含在混合物中。该混合物优选含有3重量％至5重量％，优选3.15重量％至4.85重量％，更优选4.0重量％至4.75重量％，甚至更优选4.25重量％至4.75重量％，特别优选4.35重量％至4.55重量％的碱性硬化剂，基于混合物的总重量。如果混合物基于混合物总重量包含3.25重量％至3.65重量％的碱性硬化剂，也可以获得良好的结果。已发现当使用少于3重量％的碱性硬化剂时，混凝土构件，尤其是饰面混凝土层，硬化太慢。如果使用超过5重量％的碱性硬化剂，硬化会过快开始，从而导致混凝土构件，尤其是饰面混凝土层，不能再良好地压实。
根据本发明，混合物含有水。该混合物优选含3重量％至7重量％，优选3.5重量％至6.5重量％，更优选4.0重量％至6.2重量％，甚至更优选4.2重量％至4.9重量％，特别优选4.2重量％至4.8重量％的水，基于混合物的总重量。如果混合物包含基于混合物总重量的5.2重量％至6.2重量％的水，也会获得良好的结果。
除了粘合剂、水、粒状材料和碱性硬化剂这些组分之外，该混合物还可以包含其他组分。例如，该混合物还可以包含一种或多种掺和物，例如砾石、砂砾、沙子、珍珠岩、硅藻土或蛭石。该混合物优选包含水泥和/或一种或多种掺和物，例如砾石、砂砾、沙子、珍珠岩、硅藻土或蛭石，和/或一种或多种添加剂，其选自增塑剂、消泡剂、保水剂、分散剂、颜料、纤维、可再分散粉末、润湿剂、浸渍剂、络合剂和流变添加剂。
替代性地，该混合物优选不含水泥。由此尤其可以生产具有有利的二氧化碳平衡的混凝土构件。
该混合物有利地包含硬化调节剂。尤其考虑缓凝剂和/或促凝剂作为硬化调节剂。
使用上述添加剂可以很好地控制混合物的性质。使用上述添加剂尤其可以很好地控制硬化行为。
基于混合物的总重量，混合物优选含有0.1重量％至2重量％，更优选0.4重量％至1.5重量％的添加剂。该混合物有利地含有0.025重量％至0.097重量％或1.5重量％至2重量％的缓凝剂和/或促凝剂。
根据本发明的混凝土构件优选具有根据DIN 1045-2C0或C01标准的压实等级。混凝土构件优选是混凝土块、混凝土板、混凝土墙构件或混凝土台阶。
本发明还提供了一种生产根据本发明的混凝土构件的方法，该方法包括以下步骤：
a.制备含有以下组分的组合物
i.粒状材料，
ii.选择性的颜料，
iii.选择性的填料，
iv.水，
v.潜在水硬性粘合剂和/或凝硬性粘合剂，和
vi.碱性硬化剂，
b.混合各组分以获得混合物，
c.将混合物填充到至少一个模具中，
d.压实混合物以获得至少一种生混凝土构件。
混合物优选在至少一个模具中压实。压实可以通过冲压和/或振动进行。
方法步骤优选地以上面指定的顺序执行。
此外，组合物的组分有利地以给定的顺序进料。已经发现，当以上述顺序添加组分时，混合物易于加工。如果组合物的组分在进料期间已经混合，也已证明是有利的。
上述针对根据本发明的混凝土构件所述的内容相应地适用于粒状材料、填料、水、潜在水硬性粘合剂和/或凝硬性粘合剂和碱性硬化剂，尤其是在组分的使用量方面。
此外，该组合物还可以包含上面列出的其他组分，例如掺和物、添加剂、缓凝剂和/或促凝剂。掺和物、添加剂、缓凝剂和/或促凝剂有利地与水或选择性的颜料一起进料加入，优选与水一起进料加入。
在根据本发明的方法中，可以设计混凝土构件的表面。根据一个实施形式，在压实之前，在至少一个的模具中的混合物上施加一份含有(a)含量为65至95重量％，优选75至85重量％的平均粒径为0.1至5mm的撒入组分，和(b)含量为5至35重量％，优选15至25重量％的粘合剂的造粒材料，上述含量基于该造粒材料的总组成。
通过使用这些浓度范围内的撒入组分和粘合剂，造粒材料可以很好地锚固在混凝土构件的表面上。
本领域技术人员将平均粒径理解为指有相同数量的直径较大和较小的颗粒。平均粒径可以例如通过过筛来确定。
为了根据本发明的方法的该实施形式生产特别美观的混凝土构件，已证明有利的是，饰面混凝土层具有诸如颜色或光泽度的光学特性并且造粒材料具有与此不同的光学特性。例如，这使得可以创建看起来类似于天然石头的自然结构的火焰状、纹理状或斑点状表面。
根据该实施形式，造粒材料优选通过施加装置施加到混合物上。施加装置可以具有至少一个喷淋装置、离心盘、桨轮、抛掷臂和/或弹射器，至少一份造粒材料被供给到上述设备。这些设备可以在模具上方或模具旁边移动，也可以以不同的时间间隔为其供给不同的份。这样，造粒材料可以均匀地施加到混合物上。还发现，根据本发明的方法可以以这种方式特别经济地实施。
施加装置有利地具有至少一个包含造粒材料的进料容器，其具有进料条，其中进料容器以均匀或不均匀的速度引导经过模具。
在此，优选地，将规则地和/或不规则地和/或间歇地执行的振动或振动冲击施加在进料条上。
优选沿进料条的延伸将不同的饰面材料和/或饰面材料的不同部分供给至进料条。
此外，如果进料容器连接在用于混凝土、优选饰面混凝土的进料车的前边缘上，也已证明是有利的。
例如在EP 2 910 354 A1中说明了具有至少一个带有进料条的进料容器的施加装置的可能构造。具有至少一个带有进料条的进料容器的施加装置的示例是具有至少一个腔室的填充车。造粒材料可以包含在该腔室中。填充车也可以具有由隔板隔开的两个或更多个腔室。在这种情况下，根据本发明的混合物有利地包含在填充车的第一腔室中。造粒材料优选包含在第二腔室中。另外的腔室可以含有具有不同特性的其他粒状材料，例如具有不同的颜色。填充车可以沿着导轨移动经过模具。
具有造粒材料的腔室可以具有施加部件。施加部件可以从腔室中取出。腔室可以具有一个或多个施加部件。
施加部件优选具有带有至少一个、优选多个孔的穿孔进料板和进料部件。这些孔可以统一地、或者呈图案排列在进料板上。这些孔可以具有相同或不同的直径。进料板可以是平的或弯曲的。进料板也可以设计为圆柱形的。进料板尤其可以形成进料条。
进料部件可以不同地设计。例如，进料部件可以具有轴，叶片固定在该轴上，该轴可以围绕轴的纵轴旋转。造粒材料优选位于由轴的两个叶片和进料板的所属区段形成的中间空间中。通过轴绕其纵轴旋转，叶片将造粒材料推过进料板上的孔，从而将其施加到混合物上。这种进料部件优选与弯曲的进料板结合使用。
进料部件也可以设计成梳状。在这种情况下，梳状进料部件优选可移动地放置在平坦的进料板上。造粒材料优选位于进料板上的梳齿之间。通过在进料板上移动梳子，将造粒材料挤压通过进料板上的孔，从而施加到混合物上。
进料部件也可以是穿孔板。穿孔板优选放置在平坦的进料板上。造粒材料优选位于进料板上的穿孔板的孔中。通过在进料板上移动穿孔板，将造粒材料挤压通过进料板的孔，从而施加到混合物上。
最后，进料部件也可以是可自由移动的部件，其优选布置在圆柱形进料板内部。造粒材料优选也布置在圆柱形进料板内部。在此，可自由移动的部件能够通过其重量将造粒材料挤压通过进料板的孔。通过移动，尤其是旋转圆柱形进料板，将造粒材料挤压通过进料板的孔并因此施加到混合物上。
施加部件有利地还包括另外的组件，例如可以移动进料部件的致动器。该致动器可以与电动机连接，该电动机可以优选地由电子控制装置控制。施加部件还可以具有致动器杆，与凸轮接合的凸轮从动件和/或传动装置。
根据本发明的方法的优选实施形式，施加装置具有至少一个管接头，为该管接头供给一份或多份造粒材料，并且将这些造粒材料份通过该管接头被撒出、投掷、射出和/或掉落到饰面混凝土层上。如果管接头的端部以喷嘴的方式设计，则在模具上会实现特别好的分布。
实际测试表明，如果借助于预应力的、弹簧加载的活塞，通过突然释放该活塞的锁定以抛出材料而进行喷射，根据本发明的方法产生良好的分布。
施加装置可以优选地在模具上方和/或模具旁边移动。其可以具有或实现不同的运动速度，其中顿挫的运动也是有利的。根据模具的大小和施加装置中造粒材料的颜色，可以为一个模具使用多个以及不同的装置，以实现更均匀的施加或造粒材料的特殊特征性的施加图案。
在施加装置中优选使用挡板，因为这种盘形轮或抛掷臂以及管接头可能具有更广泛的散射。
若干份造粒材料可以顺次由施加装置抛出，其中其可以是不同的造粒材料，如上所述。
造粒材料中所含的粘合剂优选为例如水泥、水硬石灰、石膏或水玻璃等无机粘合剂，或者粒状材料中所含的粘合剂为例如塑料分散体、丙烯酸酯树脂、醇酸树脂、环氧树脂、聚氨酯、溶胶-凝胶树脂或有机硅树脂乳液等有机粘合剂。这些粘合剂特别容易与混凝土构件一起处理。此外，其对方法没有额外的要求。此外，这些粘合剂使造粒材料能够很好地锚固在混凝土构件上。
根据混凝土构件所需的视觉外观，可以使用具有不同平均粒径的撒入组分。平均粒径为0.1至1.8mm的撒入组分可用作撒入组分。或者，可以使用平均粒径为1.2至5mm的撒入组分。
优选使用平均粒径为0.1至1.2mm的撒入组分作为撒入组分。
造粒材料还可以包含小石料颗粒，从而可以将具有不同颜色的不同类型的材料，包括半宝石或宝石或云母或金属碎片或塑料颗粒或玻璃颗粒的颗粒引入到表面混凝土层或饰面混凝土层中。造粒材料也可以是任何石料混合物。
如果撒入组分是或包含石料混合物，则已证明对于根据本发明的方法特别实用。这使得能够生产非常接近天然石材外观的混凝土构件。
在根据本发明的方法中，撒入组分优选至少包含选自半宝石、宝石、云母、金属碎片、玻璃和塑料颗粒的材料。使用这些材料实现了非常经济的方法。
在根据本发明的方法中，造粒材料尤其可以具有最大为2mm粒径的分级颗粒组成。
在根据本发明的方法中，可以用刷子加工至少一个的生混凝土构件的表面和/或边缘并由此将其结构化和/或粗糙化和/或平滑化和/或加工掉边缘突起。这可以进一步增强装饰性视觉外观。
在压实之前，但优选在压实之后，可以在硬化之前或之后将优选为无色的有机或无机试剂施加到混凝土构件的表面上。这涉及浸渍、密封或涂覆混凝土构件。尤其可以将密封剂和/或浸渍剂施加到至少一个的生混凝土构件的表面上。这样的程序为混凝土构件增加了一层保护层，其额外地进一步提高了混凝土构件的耐用性和使用寿命。该层还可以作为斑点保护，另外还可以防止石灰风化。
优选在根据本发明的方法中硬化生混凝土构件以获得混凝土构件。在硬化之后，优选地通过研磨、喷砂、刷涂和/或结构化混凝土构件来加工混凝土构件。
具体实施方式
为了进一步解释，下面列出了非限制性的示例。
示例
材料
粘合剂混合物：主要含有潜在水硬性粘合剂和凝硬性粘合剂。
粒状材料：在筛孔宽度为2mm时过筛量为72.5重量％，在筛孔宽度为0.25mm时过筛量为7.5重量％的石料颗粒。
填料：石粉、飞灰和/或磨碎的矿渣砂的混合物，在0.025mm的筛孔宽度下过筛量为97重量％，在0.015mm的筛孔宽度下过筛量为63重量％。
碱性硬化剂：75％的硅酸。
颜料：金属氧化物颜料。
添加剂：缓凝剂/促凝剂。
造粒材料：含有80重量％的平均粒径为0.7mm的小石料颗粒和20重量％的无机粘合剂。
根据DAfSt指南“混凝土构件的保护和修复”，第4部分，第5.5.11节确定附着抗拉强度。与此不同，选择50mm的钻孔深度。
示例1：
先后将61重量％的粒状材料、1.1重量％的颜料、6.8重量％的填料、4.4重量％的水、22.3重量％的粘合剂混合物、4.36重量％的碱性硬化剂和0.04重量％的添加剂添加到混合容器中以获得组合物，其中上述数据基于组合物的总重量。然后将该组合物在混合容器中混合以获得混合物。将由此获得的混合物填充到模制板的模具中作为饰面混凝土层，在该模具中已经存在生混凝土。饰面混凝土层具有基本颜色。然后通过冲压将混合物在模具中压实，由此获得生混凝土构件。移除模具时没有观察到生混凝土构件的撕裂。脱模后，生混凝土构件的附着抗拉强度超过1.5MPa(测试年龄56天)。硬化后，获得的混凝土构件在视觉上很有吸引力。在6个月的时间里，混凝土构件的装饰性能没有出现明显的褪去或任何其他恶化。
示例2：
依次加入67重量％的粒状材料、1.1重量％的颜料、4.4重量％的水、23.1重量％的粘合剂混合物、4.36重量％的碱性硬化剂和0.04重量％的添加剂到混合容器以获得组合物，上述数据基于组合物的总重量。然后将该组合物在混合容器中混合以获得混合物。将由此获得的混合物填充到模制板的模具中作为饰面混凝土层，在该模具中已经存在生混凝土。饰面混凝土层具有基本颜色。然后通过冲压将混合物在模具中压实，由此获得生混凝土构件。移除模具时没有观察到生混凝土构件的撕裂。脱模后，生混凝土构件的附着抗拉强度超过1MPa(测试年龄56天)。硬化后，获得的混凝土构件在视觉上很有吸引力。在6个月的时间里，混凝土构件的装饰性能没有出现明显的褪去或任何其他恶化。
示例3：
示例3与示例1相同，除了不同之处在于在冲压步骤之前通过离心盘将造粒材料施加到饰面混凝土层上。离心盘的平面与模制板表面间隔一定距离地大致平行定向。施加装置能够在模制板上移动，因此可以任意到达模具中的所有饰面混凝土层。在离心盘上方布置有漏斗，将造粒材料填充到其中。通过设置在下漏斗开口上的打开和关闭装置可以将任意份量的造粒材料引导到离心盘上。原则上，可以在离心盘上方布置多个含有不同造粒材料的漏斗，以便能够将不同剂量的不同造粒材料投掷到饰面混凝土层的表面上。离心盘的转速及其相对于模制板的高度也可以任意进行调整和改变，即使在投掷运动期间也是如此，沿着模具的运动速度也是一样的情况。根据移除模具时观察到的情况，生坯混凝土构件没有撕裂。脱模后，生混凝土构件的附着抗拉强度超过1.5MPa。硬化后，获得的表面有斑点的混凝土构件在视觉上很有吸引力。在6个月的时间里，混凝土构件的装饰性能没有出现明显的褪去或任何其他恶化。
示例4(比较例)
示例4与示例1相同，除了不同之处在于粒状材料在筛孔宽度为2.0mm时过筛量为100％，在筛孔宽度为0.25mm时过筛量为31.5％。然后将该组合物在混合容器中混合以获得混合物。将由此获得的混合物填充到模制板的模具中作为饰面混凝土层，在该模具中已经存在生混凝土。饰面混凝土层具有基本颜色。然后通过冲压将混合物在模具中压实，由此获得生混凝土构件。然而，在脱模时，混凝土构件的表面和/或饰面层的一些部分被撕掉，这导致表面受损。这些混凝土构件不能再使用了。对混凝土构件未损坏部分的附着抗拉强度的测定表明，混凝土构件的附着抗拉强度显著小于1MPa。
示例5
示例5与示例1相同，除了不同之处在于不使用添加剂(促凝剂/缓凝剂)。
然后将该组合物在混合容器中混合以获得混合物。以这种方式获得的混合物具有非常短的适用期，即混合物仍然可以从混合容器填充到模具中的时间跨度。
示例6：
依次添加63.5重量％的粒状材料、1.1重量％的颜料、4.01重量％的水、27.2重量％的粘合剂混合物、4.15重量％的碱性硬化剂和0.04重量％的添加剂到混合容器以获得组合物，上述数据基于组合物的总重量。然后将该组合物在混合容器中混合以获得混合物。将由此获得的混合物填充到模制板的模具中作为饰面混凝土层，在该模具中已经存在生混凝土。饰面混凝土层具有基本颜色。然后通过冲压将混合物在模具中压实，由此获得生混凝土构件。移除模具时没有观察到生混凝土构件的撕裂。脱模后，混凝土构件的附着抗拉强度略小于1MPa(测试年龄56天)。
Claims (23)
1.包括核心混凝土层和饰面混凝土层的混凝土构件，其中所述饰面混凝土层通过压实和硬化包含潜在水硬性粘合剂和/或凝硬性粘合剂、水、粒状材料和碱性硬化剂的混合物得到，其中所述粒状材料在2mm的筛孔宽度下具有35.5重量％至99.5重量％的过筛量，并且在0.25mm的筛孔宽度下具有2.5重量％至33.5重量％的过筛量，分别基于粒状材料的总重量。
2.根据权利要求1所述的混凝土构件，其特征在于，所述粒状材料在2mm的筛孔宽度下具有42.5重量％至99.5重量％、更优选56.5重量％至98.5重量％、特别优选72.5重量％至97.5重量％的过筛量，并且在0.25mm的筛孔宽度下具有2.5重量％至27.5重量％，更优选2.5重量％至22.5重量％，甚至更优选2.5重量％至21.5重量％，特别优选2.5重量％至8重量％或11.5重量％至21.5重量％的过筛量，基于粒状材料的总重量。
3.根据权利要求1或2所述的混凝土构件，其特征在于，所述粒状材料具有1.59至3.62、优选1.61至3.17、特别优选1.61至2.55的粒度模数。
4.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，基于混合物的总重量，所述混合物含有55重量％至80重量％，优选60重量％至75重量％，更优选60重量％至72重量％，特别优选60重量％至65重量％，特别是60至64重量％或者67重量％至72重量％的粒状材料。
5.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，基于混合物的总重量，所述混合物含有1重量％至30重量％，优选1重量％至20重量％，更优选5重量％至18重量％，甚至更优选5重量％至15重量％，甚至更优选5重量％至10重量％，特别优选6重量％至8重量％的填料。
6.根据权利要求5所述的混凝土构件，其特征在于，所述填料在0.025mm的筛孔宽度下具有63重量％至99重量％，优选68重量％至99重量％，更优选90重量％至99重量％，特别优选95重量％至99重量％的过筛量，并且在筛孔宽度为0.015mm时具有38重量％至73重量％，优选58重量％至67重量％，特别优选61重量％至66重量％的过筛量，基于填料的总重量。
7.根据权利要求5或6所述的混凝土构件，其特征在于，所述填料选自飞灰、矿渣砂、岩粉，优选分级岩粉、石灰石粉，优选分级石灰石粉、及其混合物。
8.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，所述混合物含有15重量％至40重量％，优选20重量％至30重量％，更优选20重量％至24重量％，或者26重量％至29重量％，特别优选22重量％至24重量％的潜在水硬性粘合剂和/或凝硬性粘合剂，基于混合物的总重量。
9.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，潜在水硬性粘合剂选自残渣、高炉炉渣，优选矿渣砂，尤其是磨碎的矿渣砂、电热磷矿渣、钢渣及其混合物，和/或所述潜在水硬性粘合剂中的(CaO+MgO)∶SiO2的摩尔比为0.8至2.5，优选为1.0至2.0。
10.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，凝硬性粘合剂选自无定形二氧化硅、沉淀二氧化硅、热解二氧化硅、微硅粉、玻璃粉末、飞灰，如褐煤粉煤灰或硬煤粉煤灰、偏高岭土、天然白榴火山灰，如凝灰岩、浮石凝灰岩或火山灰、天然和合成的沸石、及其混合物。
11.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，碱性硬化剂选自碱金属氧化物、碱金属氢氧化物、碱金属碳酸盐、碱金属硅酸盐、碱金属铝酸盐及其混合物，优选选自碱金属氢氧化物、碱金属硅酸盐及其混合物。
12.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，所述混合物含有3重量％至5重量％，优选3.15重量％至4.85重量％，更优选3.25重量％至3.65重量％或4.0重量％至4.75重量％，甚至更优选4.25重量％至4.75重量％，特别优选4.35重量％至4.55重量％的碱性硬化剂，基于混合物的总重量。
13.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，所述混合物含有3重量％至7重量％，优选3.5重量％至6.5重量％，更优选4.0重量％至6.2重量％，甚至更优选4.2重量％至4.9重量％或5.2重量％至6.2重量％，特别优选4.2重量％至4.8重量％的水，基于混合物的总重量。
14.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，所述混合物包含硬化调节剂，尤其缓凝剂和/或促凝剂。
15.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，所述混合物包含水泥和/或一种或多种掺和物，例如砾石、砂砾、沙子、珍珠岩、硅藻土或蛭石，和/或一种或多种添加剂，其选自增塑剂、消泡剂、保水剂、分散剂、颜料、纤维、可再分散粉末、润湿剂、浸渍剂、络合剂和流变添加剂。
16.根据前述权利要求中任意一项所述的混凝土构件，其特征在于，所述混凝土构件是混凝土块、混凝土板、混凝土墙构件或混凝土台阶。
17.生产根据权利要求1至16中任意一项所述的混凝土构件的方法，所述方法包括以下步骤：
a.制备含有以下组分的组合物
i.粒状材料，
ii.选择性的颜料，
iii.选择性的填料，
iv.水，
v.潜在水硬性粘合剂和/或凝硬性粘合剂，和
vi.碱性硬化剂，
b.混合组合物以获得混合物，
c.将混合物填充到至少一个模具中，
d.压实混合物以获得至少一个生混凝土构件。
18.根据权利要求17所述的方法，其特征在于，所述组合物的组分以给定的顺序进料。
19.根据权利要求17或18所述的方法，其特征在于，在压实之前，在至少一个的模具中在混合物上施加一份造粒材料，其含有(a)含量为65至95重量％的平均粒径为0.1至5mm的撒入组分，和(b)含量为5至35重量％的粘合剂，上述含量基于所述造粒材料的总组成。
20.根据权利要求19所述的方法，其特征在于，所述造粒材料中所含的粘合剂为无机粘合剂，如水泥、水硬石灰、石膏或水玻璃；或者造粒材料中所含的粘合剂为有机粘合剂，如塑料分散体、丙烯酸酯树脂、醇酸树脂、环氧树脂、聚氨酯、溶胶-凝胶树脂或有机硅树脂乳液，和/或使用平均粒径为0.1至1.8mm或1.2至5mm的撒入组分作为撒入组分，和/或所述撒入组分是或包含石料混合物，或者所述撒入组分至少包含选自半宝石、宝石、云母、金属碎片、玻璃和塑料颗粒的材料。
21.根据权利要求17至20中任意一项所述的方法，其特征在于，用刷子加工至少一个的生混凝土构件的表面和/或边缘并由此将其结构化和/或粗糙化和/或平滑化和/或加工掉边缘突起。
22.根据权利要求17至21中任意一项所述的方法，其特征在于，将密封剂和/或浸渍剂施加到所述至少一个的生混凝土构件的表面上。
23.根据权利要求17至22中任意一项所述的方法，其特征在于，硬化生混凝土构件以获得混凝土构件，其中优选在硬化之后，通过研磨、喷砂、刷涂和/或结构化混凝土构件来加工混凝土构件。
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| DE202019102157U1 (de) | 2019-04-15 | 2019-04-29 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Werksteinplatte als Bodenbelag |
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2019
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Also Published As
| Publication number | Publication date |
|---|---|
| EP4028371A1 (de) | 2022-07-20 |
| IL291208B1 (en) | 2023-03-01 |
| EP4321317A2 (de) | 2024-02-14 |
| DE102019124726A1 (de) | 2021-03-18 |
| RS64842B1 (sr) | 2023-12-29 |
| FI4028371T3 (fi) | 2023-12-04 |
| PL4028371T3 (pl) | 2024-03-18 |
| JP7411070B2 (ja) | 2024-01-10 |
| IL291208B2 (en) | 2023-07-01 |
| IL291208A (en) | 2022-05-01 |
| ES2966793T3 (es) | 2024-04-24 |
| HRP20231554T1 (hr) | 2024-03-15 |
| WO2021047875A1 (de) | 2021-03-18 |
| US20230138864A1 (en) | 2023-05-04 |
| EP4028371B1 (de) | 2023-09-27 |
| CA3148392A1 (en) | 2021-03-18 |
| EP4321317A3 (de) | 2024-05-08 |
| PT4028371T (pt) | 2023-12-12 |
| DK4028371T3 (da) | 2023-12-04 |
| SI4028371T1 (sl) | 2024-01-31 |
| HUE064360T2 (hu) | 2024-03-28 |
| JP2022537603A (ja) | 2022-08-26 |
| CA3148392C (en) | 2024-03-19 |
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