DE19509449A1 - Fluid-tight strong concrete-like building material prodn. - Google Patents

Abstract

A method of producing tight, high strength, concrete-like building materials involves initially intensively mixing 5 - 9.8 parts hydraulically active brown coal filter ash and 0.2 - 5 parts hard coal filter ash with at most 2 pts. water (w.r.t. 10 pts. dry matter) and then processing to a mix, taking into account the total minimum water requirement of the ash mix.

Description

The invention relates to a method for producing dense and high solid concrete-like building materials by using hydraulic active lignite filter ash and hard coal filter ash. Here, the hydraulically active lignite filter ash as self-hardening and as stimulator for pozzolanic reactions of the coal filter ash.

There has been no shortage of attempts to filter lignite filter ash from coal dust fired power plants.

The processing of these ashes instead of cement due to their binding However, mediocre properties have not yet led to the desired Respectively.

The strengthening properties of some ashes, especially hard coal filter ash, were only by special measures, such as by adding Excitation, through special mechanical treatment or through pressure hardening release, but without achieving a cement replacement (DD-PS 2 74 206). It was also trying to find artificial supplements for the construction industry Manufacture using hard coal filter ash (DE-PS 35 39 264). As well is said to be produced by producing large blocks of hard coal filter ash and containing CaO Binder with subsequent crushing and re-pressing a building material can be produced (DE-PS 35 24 693).

Show through their special material composition (calcareous) hydraulically active brown coal filter ash has its own hardening behavior, the activation of the strengthening mineral and glass phases and the addition of other components is of great importance. Because of of these previously unsettled circumstances, they were used as mineral binder or as a mineral binder component only in comparatively small scope.

By making an ash-water suspension with a high Mixing water content could be achieved by the complete particles wetting the binding properties of the lignite filter ash are released (DD-PS 2 44 472, DD-PS 2 44 545, DD-PS 2 44 546), according to which Suspension production other binders and other additives such. B. Fibers can also be added. With a high addition water quantity, however, would have to be related to production, consolidation and processing excess water again from the final mixture using a special technical and technological effort are removed.

The determination of a recipe for the practical use of an ash or an ash mixture can be made in different ways will.  

In this regard, DE-PS 41 03 412 states:
On the basis of individual ash components of different grain sizes, an experimentally designed water demand function enables the percentage of the components, the specific water demand and the technological limits within which the production of a dispersion for construction and sealant products to be made. The compaction of the grain structure under the influence of water is brought about by adding the amount of water which is required to reach the upper yield point to the ash mixture when shear movements are applied. To do this, there must be two ash fractions that differ significantly in terms of their grain size distribution.

The inclusion of the water demand function required for processing and their compliance, however, requires a very high technical, techno logical and analytical effort, so that this procedure out construction-technical reasons for the general construction practice are omitted:

The delivery of filter ash from modern large power plants takes place as Mixing ash of all filter stages, so that processing according to the invention is a complex separation of the mixing ash in requires individual ash fractions.

On the other hand, the invention lies on the basis of the explained prior art based on the concern, using specified according to the invention Proportion of hydraulically active brown coal filter ash and hard coal filter ash using a simple technology that can be used in practice Production of concrete-like building materials of high density and high Strength with high volume constancy with regard to manufacturing shrinkage and Enable sources.

After a large number of such experiments over many years the following recipe was developed:

Depending on their binder activity
5 to 9.8 parts of hydraulically active brown coal filter ash
0.2 to 5 parts of hard coal filter ash
with less than 2 parts of mixing water based on
10 parts dry matter
intensively mixed in the initial phase and then processed into a processable mixture with the possible addition of additives such as other binders and / or inert, reactive or partially reactive additives and / or additives and / or additives, taking into account the requirements for the overall mixture production, processing or -application and hardening of the minimum water requirements. Undesired swelling can be prevented by the added non-reactive or dwindling addition substances up to the constant volume of the hardened mixture.

The kinetic-mineralogical-chemical processes at Interaction of hydraulically active lignite filter ash and Hard coal filter ash with water examined and their own activity and that Activation behavior of hydraulically active brown coal filter ash Hard coal filter ash clarified.

This led to the discovery of a new mode of action between more or less free lime containing hydraulically active brown coal filter ash (BFA) and hard coal filter ash (SFA). It consists in the specific activating Role of such a BFA in relation to the pozzolanic reactions of a SFA:

The investigations showed that in the initial phase of hardening in the BFA water system, a higher concentration of Ca ions in the pore solution than conventional Portland cement can be found. This leads to a higher turnover of the silicon-containing glass phases of the SFA and thus to a higher yield of the strengthening hydrate phases which form. In order to obtain sufficient Ca ⁺⁺ ions for the pozzolanic reaction of the SFA, the range of the mixing ratio BFA / SFA must be restricted and the amount of added water must be kept low. The different distribution of the individual grain size groups of both the BFA and the SFA must also be taken into account when determining a mixing ratio BFA / SFA. In addition, the physical properties of the hard coal filter ash, such as a high proportion of spherical particles, their fine grain size and their low water consumption, have a favorable effect on the production, processability and compression behavior of the fresh mixture. The composition of such BFA / SFA mixtures was then varied within the possible above-mentioned mixing ratio range in such a way that with a still low water (total) ash ratio, taking into account the relevant requirements for the production, processing, application and hardening of the mixture ultimately formed the BFA swelling associated with water during the reaction could be reduced in a targeted manner by adding SFA accordingly. The invention is explained in more detail using exemplary embodiments:

example 1 A fine grain concrete is to be produced using comparatively high proportions of hydraulically active brown coal filter ash

9.5 parts of hydraulically active lignite filter ash and 0.5 parts of coal filter ash combined and mixed intensively. Then, with regard to the ash mixture, 0.1 parts of mixing water added. Based on the total ash content, you then mix 20% by weight of Portland cement PZ 35 was added. Ultimately, it will be one Amount of water mixed in, based on the dry ash and the Cement gives a water / solid ratio of 0.25.

This gives you a fine grain concrete with a 3, 7 and 28 day compressive strength of 7, 15 and 28 [N / mm²].  

Example 2 A fine grain concrete is to be produced using comparatively lower proportions of hydraulically active brown coal filter ash

5.5 parts of hydraulically active lignite filter ash and 4.5 parts of coal filter ash combined and mixed intensively. Then, with regard to the ash mixture, 0.1 parts of mixing water added. Based on the total ash content, you then mix 20% by weight of Portland cement PZ 35 was added. Ultimately, it will be one Amount of water mixed in, based on the dry ash and the Cement gives a water / solid ratio of 0.25.

This gives you a very fine combination with a 3, 7 and 28 day compressive strength of 4, 9 and 16 [N / mm²].

Due to the achievable high tightness and / or high strength of the Follow the hardened, inexpensive and customarily manufactured mixture:

• - generally high mechanical-technological parameters;
• - low permeability factors for liquids and Gases;
• - if the volume is constant with regard to manufacturing Shrinkage and swelling;

and there are thus a multitude of possible uses.

So can be z. B. Fresh mixes for deep, water and Manufacture sewer construction and for seals in water and landfill construction. On the other hand, the mixture can, for. B. also for the production of dense Precast elements (such as water pipes, gas tanks), prefabricated shafts and conventional concrete goods (such as wall elements, paving stones, curb and Apply lawn edging stones.

The mixture is used in steel and prestressed concrete construction with the same advantages used.

The further processing of the mixture can, as described, be more typical Way. Due to the material advantages mentioned above but also realize non-concrete processing, e.g. B. the waiver Production-related shrinkage or expansion joints with large areas Processing, monolithic casting of complicated components and a dense subsequent combination of prefabricated individual components. High strength can also be taken into account advantageously in terms of civil engineering.

The mixture produced can also contain contaminated materials enter so that immobilization of the pollutants, eg. B. toxic substances, in the cured manufacturing products.  

Such additives may also have to be mixed into the mixture produced. e.g. B. plastic regranulates that give different material properties, so z. B. sound insulation, thermal insulation and / or high strength properties.

Additives such as other binders are optionally added to the mixture and / or inert substances and / or additives and / or additives under Consideration of the for the overall mixture production, processing, -Application and hardening required minimum water requirements added and mixed. Undesired swelling can be caused by the added non-reactive or dwindling additives up to constant volume of the hardened mixture are prevented.

In addition, z. B. such components or elements without further in the manufacturing process for special composite materials and / or Unite composite elements.

Claims (5)

1. A method for producing dense and high-strength concrete-like building materials using hydraulically active brown coal filter ash and hard coal filter ash, characterized in that
5 to 9.8 parts of hydraulically active brown coal filter ash
0.2 to 5 parts of hard coal filter ash
with less than 2 parts of mixing water based on
10 parts dry matter
intensively mixed in the initial phase and then processed into a mixture, taking into account the total minimum water requirement of the ash mixture. 2. The method according to claim 1, characterized in that in the mixture Additives such as other binders and / or inert, reactive or partially reactive additives, e.g. B. fibrous substances, and / or additives and / or Admixture taking into account that for the overall mixture production, processing, application and hardening required minimum water Claim added and mixed. 3. The method according to claim 1 and 2, characterized in that in the Mixture of contaminated materials are added. 4. The method according to claim 1 and 2, characterized in that with the produced mixture renovation measures for components with high Leak tightness such as on water pipes, shafts, tubs etc. are carried out. 5. The method according to claim 1 and 2, characterized in that the Mixtures to achieve different specific material properties (such as sound and heat insulation, high strength) in one Manufacturing process to be made.