DE102005014704A1 - Production method for light materials involves performing further mixing process after foam is produced from sudsy component - Google Patents

Abstract

Reactive components are mixed with water. A bonding agent, liquid concrete additives, powdered aggregates and filler are added and mixed with the mixture of reactive components and water to produce a sudsy component which is added with air to produce foam. A further mixing process is then performed. An independent claim is also included for a light material production mechanism.

Description

The The invention relates to a method and a device for the production a lightweight material in the form of lightweight concrete and porous lightweight concrete, which in various industries, but especially in the construction industry Find application.

to It is the production of lightweight materials, including lightweight concrete known, the cement-sand-gravel mixture various additives / binder to add, on the one hand reduce the density of the concrete and the to improve the insulating properties of others. So it is known the concrete or cement sizing agent in the form of foams zuzumischen, air entraining additives z. B. aluminum paste or To add aluminum powder to the binder / cement paste or also lightweight surcharges in the form of crushed Styrofoam, glass, pearlite or pumice to incorporate.

So WO 96/04217 A1 describes a process in which by mixing inorganic binder with solid silicate lightweight aggregates, such as As pumice, perlite, foam glass, molar earth, diatomaceous earth or mixtures same with subsequent Hardening in water vapor pressure vessel, made of a lightweight material shall be.

The EP 01 27 960 B1 describes a process of the same type in which a lightweight material can also be produced by mixing ultrafine silicate dust with lime or calcareous materials.

disadvantage These lightweight materials are that for producing a pasty bulky mass high water addition is required, whereby the final products a high capillary porosity and related have relatively low strengths.

task The invention is a method and apparatus for manufacturing a lightweight material, in particular for the production of lightweight and pore lightweight concrete with higher To develop strengths, this with substantial elimination the disadvantages of the known solutions. It is also an object of the invention to provide a device with which an effective production of lightweight materials is possible, which can be integrated in existing systems and designed for mobile use.

According to the invention Task solved with the features of claims 1 and 6.

Out the dependent claims arise special designs and advantageous solutions of Invention.

at The production of lightweight materials is followed by binder limes Use, which is usually made of hydraulic binders and powdered and / or mealy surcharges exist that are mixed together.

hydraulic Binders are unlike unhydraulic binders as well Bindable in the presence of water and insoluble in water. To belong to these binders For example, Puozzolane, trass, cement and hydraulic limestones.

When Powder or flour-shaped Supplements For example, limestone or quartz flour are used.

Water- and concrete admixtures are other elements that bind to the binder be added.

The Problem with the mixture of these substances among themselves is that these not homogeneously mixed. So remain in the binder lime individual adhesive cement grains / conglomerates. The reasons lie in the fact that the binder lacks sand or gravel, which the Task to grind the cement grains during the mixing process, since the in the cement matrix remaining cement grains just in conjunction with lightweight aggregates and Air pores form defects which lead to strength losses.

at Use of foams, when added to a non-homogeneously mixed binder be and be mixed with this, the remaining sink Cement grains due their higher Weight in contrast to the foam in the final product down. This with the result that on the surface of the cement sufficient corroboration missing and a non-homogenous structure is created.

So was to increase the strength of lightweight materials, in particular to increase the strength developed a process from lightweight concrete and lightweight concrete pores, which is characterized by the fact that first for the hydraulic setting process colloidally reactive with water mixed, this mixture of solid and liquid concrete additives as well powdery Aggregates and fillers added and with the reactive binders and water in one Reactor can be mixed colloidally.

This Binder lime is the starting material for the production of lightweight and pore lightweight concrete, in the further process steps aggregates and foamer be mixed.

The Colloidal blending of the basic components of lightweight materials causes that during the mixing processes introduced a high energy in the mix will and will take over, occurring Kravitationskräfte the grinding of the granular components. Thus, no conglomerates of cement granules remain in the binder and by the colloidal dilution to be hydrated every cement grain needed water molecule is attached. It can be a low water-cement ratio too used without concrete liquefier become higher Final strengths are achieved. Due to the special colloidal mixing process the tixotropic behavior of cement is used and thus the flow properties further increased.

As a result the colloidal dilution of the reactive constituents with water, this blending process is complete within seconds the binder of the invention also be produced in a continuous process.

in the second process step, the lightweight aggregates are in solid and more fluid Form merged with the ready mixed binder and in a separate post-mixing tank prepared and then discharged for further processing.

In the production process according to the invention for the formation of lightweight materials come as reactive constituents, these are hydraulic binders, preferably Puozzolane, cement, trass and hydraulic limes. As powdery additives are Quartz flour or limestone flours and as filler fly ash in the manufacturing process brought in. The category of concrete admixtures includes condenser, Microsilica, color pigments, air-entraining agents, solidification accelerators or retarders.

When Filling and Aggregates will be expanded polystyrene (EPS), perlite, sands, Kiese, slags, cork, rubber, vermicalite, glass granules, recycled material and fibers used.

In a preferred embodiment can next Lightweight and lightweight paving also mortars of this type produced become. The only requirement is that instead of the introduced Concrete additive Mortar additive be used.

In a further preferred embodiment Is it possible, to produce normal concretes. This is such that the binder which, as described above, after colloidal mixing reactive binder with water, the addition of concrete admixtures and their subsequent colloidal Mix this mixture / binder in the heavy aggregates as sands and gravels added and in second mixing process, in a separate mixer. The thus formed Concrete is removed from the mixer and its use.

The inventive device to realize the method is characterized by its compact Training from whose individual functional elements in a commercial 10-foot container are locatable and the entire facility is designed mobile. Thus, there is the possibility this mobile device with existing material processing equipment for the Production of concretes and mortars to combine or to join, so that immediately before Place the lightweight materials of the invention can be produced.

In the mobile device for implementing the method are a Reactor for the colloidal dilution and a mixer for the aftermix and the corresponding feeders the liquid Provided additive to the reactor.

to Facility belong also reservoir and feeders for the Storage and feeder the solid additive as well as a functional module, by means of in the reactor and mixer to be introduced fillers and additives in metered Fed form become. This functional module can directly into the device according to the invention be installed or designed as an additional device, which is assigned to the container.

Further belong to the device according to the invention a delivery pump and a foam module, by means of the supplied from the Binders made in a lightweight concrete or a porous lightweight concrete becomes.

completed is the device by another functional module, by means of the solid concrete additives in the desired dosage to the reactor supplied become.

With following embodiment the invention should be closer explained become. In the accompanying Show drawing

1 : the flow diagram of a material processing plant for the production of lightweight materials with associated equipment / container,

2 : the flow chart after 1 with arranged between reactor and mixer VerschÃummmododul.

In the 1 is the invention A direction in the form of the container 7 represented in which the functionally essential elements of the device for the production of lightweight materials in the form of light and porous lightweight concrete are arranged.

Shown in the 1 also the functional integration or assignment of the device, the container 7 to a material processing plant consisting of the four storage containers / material silos 1 to 4 consists of which the abzufördernden goods via feeders 5 and supply lines 6 to the functional units of the container 7 be guided.

In the storage container 1 are the reactive components, the hydraulic binder, such as cement, stored. In the storage container 2 find the powdery aggregates in the form of quartz powder or cold stone meal recording. The Vorratsbe container 3 is with powdered filler, such as fly ash and the reservoir 4 Recipe conditionally filled with the heavy aggregates such as sands and gravels or lightweight aggregates such as glass granules and pumice.

Below the reservoir 1 to 4 are feeders 5 provided by means of which in storage containers 1 to 4 stored good to supply lines 6 promoted and over the supply lines 6 in metered and desired amount of the reactor 9 and the mixer 10 be supplied.

The container 7 is also with feeders 8th trained with the reactor 9 are connected. Furthermore, in the container 7 a functional module 15 with supply line 16 and associated weighing device 13 arranged. Likewise in the container 7 are following the mixer 10 a pump 11 provided that a discharge line 21 is assigned and further is in the container 7 a Verschäummodel 12 arranged, which in turn via a supply line to the pump 21 and a removal line 23 is trained. On the input side of the spreader module 12 is this with an air supply 22 connected.

The device according to the invention also includes a functional module 14 with weighing device, in which the fillers and additives, such as an expanded polystyrene (EPS) are embedded. This functional module 14 can both directly part of the mobile device, thus the container 7 be or be designed as an external device, the use of the device to the container 7 is assigned. About the supply line 17 is the functional module 14 with the mixer 10 connected, whereby also a connection between the function module 14 and the reactor 9 over the supply line 19 can be produced.

A connection between reactor 9 and mixers 10 is through the supply line 18 given.

To control and regulate the entire material processing plant for the production of lightweight concrete and also normal concretes and mortar is the device / container 7 with a control unit 20 trained, by means of which the entire system is computer-controlled. This has the particular advantage that a precise dosing of the individual components for the production of a binder and, as a result, of lightweight materials, the individual batches and formulations for quality assurance and detection can be logged. Furthermore, it is possible by the use of appropriate control / regulation programs, in which, for example, recipes are integrated, the entire manufacturing process, in particular the dosage of the individual components, taking into account the desired product properties of the final products to run automatically.

On the basis of in the control unit 20 entered parameters are the necessary and desired raw materials / materials through the reservoir 1 to 4 and their feeders 5 and supply lines 6 the reactor 9 and the mixer 10 provided and via the functional modules 14 ; 15 the appropriate additives and supplements are added.

If a lightweight concrete is to be produced, the process according to the invention proceeds as follows:
The storage tank 1 is using the existing control unit 20 controlled and the / in the reservoir 1 located reactive binder over the conveyor 5 in the supply line 6 guided and get over the supply line 6 to the reactor 9 , At the same time, water is flowing through one of the feeders 8th in the reactor 9 initiated, which in the reactor 9 is mixed with the reactive binder colloidally.

The liquid concrete admixtures are via a further feeder 8th in the reactor 9 entered. The solid concrete admixtures are located in the functional module 15 and are provided via provided feeders and the supply line 16 also in the reactor 9 directed.

The powdery additives are from the reservoir 2 carried away and by means of the supply line 6 also to the reactor 9 fed. In the reactor 9 Be equal if the in the reservoir 3 embedded powdered filler over the intended feed conveyor 5 and the supply line 6 entered.

In the reactor 9 the colloidal mixture of the entered substances and the formed Sus takes place Pension / Bindelleim is via the supply line 18 in the downstream mixer 10 given and with the from the function module 14 over the supply line 17 supplied aggregate intensively mixed. After intensive mixing, the ready-mixed lightweight concrete by means of the downstream pump 11 from the mixer 10 abgefördert and on the discharge line 21 transported away for further processing.

The process for producing a lightweight porous concrete is described with reference to FIG 2 as follows:
The first four process steps for the production of a porous lightweight concrete proceed analogously to the first four process steps for producing a lightweight concrete.

So the reactive binder from the reservoir 1 via a feed conveyor 5 and the supply line 6 to the reactor 9 guided and at the same time water passes through one of the feeders 8th in the reactor 9 , The solid concrete admixtures are from the functional module 15 over the supply line 16 the reactor 9 and the liquid concrete admixtures are via a line of the feeder 8th the reactor 9 fed. The powdered aggregates and the powdered fillers are removed from the storage containers 2 and 3 over the designated feeders 5 and the supply line 6 also in the reactor 9 initiated. Here the colloidal mixing of these components takes place and the suspension / binder lime thus formed is conveyed via the supply line 18 in the mixer 10 guided, there again mixed and from the mixer 10 over the pump 11 and the supply line 21 the spreader module 12 fed. About an air supply 22 becomes the spreader module 12 Supplied air, it takes place the foaming of the components, so that from the Verschäummodul 12 via the discharge line 23 a finished pore lightweight concrete can be removed and fed to its further use.

The inventive method and the proposed device are also suitable to produce a lightweight concrete with lightweight aggregates and air, wherein, as already described in the above two embodiments, the first four steps proceed analogously, that is, the individual components are in the reactor 9 , entered as described and mixed there colloidally. From the reactor 9 This suspension, as in the 1 shown in the between the reactor 9 and the mixer 11 now intermediate Verschöummodul 12 guided, the connection between the Verschäummodul 12 to the reactor 9 and to the mixer 10 is through the supply line 18 produced. In the spreader module 12 is via the air supply 22 Air introduced, the supplied suspension foamed and in this state in the mixer 10 passed, there again mixed and then by means of the pump 11 and the discharge line 21 removed from the plant.

Furthermore, with the presented method and the device a concrete in normal execution can be produced, as described below with reference to 1 that is, the reactive constituents and water are in the reactor 9 collodially mixed, at the same time the liquid and solid concrete admixtures in the reactor 9 passed, in this colloid mixed and in this mixed form from the reactor 9 directly via the supply line 18 in the mixer 10 pumped. In parallel, from the reservoir 4 the heavy aggregates such as sands and gravels over the assigned feed conveyor 5 and the supply line 6 in the mixer 10 initiated and thoroughly mixed with the suspension already in it. After mixing, the finished concrete is pumped over 11 and the discharge line 21 discharged.

The provided in the device Verschöummodul 12 finds application in the production of lightweight concrete, lightweight pore concrete and lightweight concrete with air aggregates, which preferably consists of tubular joined components, inside the Verschöummoduls 12 form an injection area, a mixing area and a foaming area. In the injection area, the material flows, formed from binder lime and the air, via the supply line 18 and the air supply 22 introduced and brought together in this area. The air is in the axial direction of the Verschäummodul 12 and the binder in the radial direction in the Verschäummodul 12 brought in. In the downstream mixing area there is a continuous mixing of these introduced components. In the subsequent Verschäumbereich a final valid foaming takes place. At the same time, the expansion area serves as the contact zone of the turbulent flows present in the binder mixture.

For the formation of a porous lightweight concrete with a substance density of 380 kg / m ³ , for example, from the reservoir 1 a cement and water in the manner already described in the reactor 9 given a limestone powder in the range of 5 to 30% by volume based on the cement content, this at a water-cement value of 0.3. After colloidal mixing in the reactor 9 This suspension / binder lime, consisting of 10% by volume of binder lime and 90% by volume of foam, consisting of foaming agent-water mixture, is passed through the lathering module 12 in the mixer 10 spent, mixed there, then on the pump 11 in the discharge line 23 fed to its further use.

To Lightweight materials produced according to the invention are particularly suitable for the production of bricks, for the filling of cavities as well as of EPS-shaped bricks and natural stone masonry and particularly suitable for one Thermal insulation and Fire protection plaster, also for backfilling Tübbingen in tunnel construction as total thermal insulation, but also for the construction of road substructures.

Claims (10)

Process for the production of lightweight materials in the form of lightweight concrete and porous lightweight concrete, in the binder and aggregates are mixed in the - for the hydraulic setting process colloidally reactive with water be mixed up, - this one Binders in solid and liquid Concrete additive and powdery Aggregates and fillers added and mixed up colloidally, - yourself further mixing process follows, then the mixture for the production of a porous lightweight concrete one Verschäummodul supplied becomes, - in which is introduced into the mixture air, mixed with this and then foamed or - for the production of a lightweight concrete, after the reactive binder with water as well as with the solid and liquid Concrete admixtures and the powdered aggregates and fillers are added to the Verschöummodul and afterwards - another Mixing process connects. Method according to claim 1, characterized in that that as reactive constituents Puozzolane, cement, trass and hydraulic Limes are used. Method according to claim 1, characterized in that that as solid and liquid Concrete admixture condenser, Microsilica, color pigments, air-entraining agents, solidification accelerators or retarders Find use. Method according to claim 1, characterized in that that as powdered Aggregates and fillers Quartz flours, cold stone flours and fly ash are used. Process according to Claims 1 and 3, characterized that instead of concrete admixture mortar additive for the production a mortar involved in the process. Device for carrying out the method according to claim 1, characterized in that the device as a compact mobile assembly in the form of a container ( 7 ) in which a reactor ( 9 ), a mixer ( 10 ), Feeders ( 8th ), a functional module ( 15 ) with weighing device ( 13 ), a pump ( 11 ) and a Verschäummodul ( 12 ), a second functional module ( 14 ) the container ( 7 ) and the individual functional units of the device can be assigned via feeders ( 8th ), Supply lines ( 6 ; 16 ; 17 ; 18 ) are interconnected. Device according to claim 6, characterized in that the container ( 7 ) to a material treatment plant, which from individual storage containers ( 1 ; 2 ; 3 ; 4 ) with associated conveyors ( 5 ) is assignable, while the reactor ( 9 ) via a supply line ( 6 ) with the storage containers ( 1 ; 2 ; 3 ) and via a supply line ( 16 ) with the function module ( 15 ) connected is. Device according to claims 6 and 7, characterized in that the feeding devices ( 8th ) in the reactor ( 9 ), this via the supply line ( 18 ) with the mixer ( 10 ), in the supply line ( 18 ) the Verschäummodul ( 12 ) and the mixer ( 10 ) a pump ( 11 ) with subsequent discharge line ( 21 ) assigned. Device according to claims 6 and 7, characterized in that the Verschäummodul ( 12 ), seen in the flow direction, behind the mixer ( 10 ) and the pump ( 11 ), the Verschuummodul ( 12 ) an air supply ( 22 ) and with a discharge line ( 23 ) is trained. Device according to claims 6 to 9, characterized in that the container ( 7 ) a control unit ( 20 ) assigned.