EP1141497B1 - Thin-walled component made from hydraulically hardened cement paste material and method for the production thereof - Google Patents

Thin-walled component made from hydraulically hardened cement paste material and method for the production thereof Download PDF

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Publication number
EP1141497B1
EP1141497B1 EP99970707A EP99970707A EP1141497B1 EP 1141497 B1 EP1141497 B1 EP 1141497B1 EP 99970707 A EP99970707 A EP 99970707A EP 99970707 A EP99970707 A EP 99970707A EP 1141497 B1 EP1141497 B1 EP 1141497B1
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Prior art keywords
steel wool
mass
component according
component
process according
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EP99970707A
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German (de)
French (fr)
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EP1141497A1 (en
Inventor
Christian Bechtoldt
Rolf-Rainer Schulz
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Dyckerhoff GmbH
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Dyckerhoff GmbH
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    • 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
    • B28B1/24—Producing shaped prefabricated articles from the material by injection moulding
    • 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
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/012—Discrete reinforcing elements, e.g. fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/02—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance
    • E04C5/04—Mats
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G23/00—Working measures on existing buildings
    • E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G23/00—Working measures on existing buildings
    • E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
    • E04G23/0203—Arrangements for filling cracks or cavities in building constructions
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/90—Direct application of fluid pressure differential to shape, reshape, i.e. distort, or sustain an article or preform and heat-setting, i.e. crystallizing of stretched or molecularly oriented portion thereof
    • Y10S264/904—Maintaining article in fixed shape during heat-setting
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24074—Strand or strand-portions
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24124—Fibers
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24562—Interlaminar spaces
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24636—Embodying mechanically interengaged strand[s], strand-portion[s] or strand-like strip[s] [e.g., weave, knit, etc.]
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/24992—Density or compression of components
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249932—Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/298—Physical dimension

Definitions

  • the invention relates to a thin-walled, flat component of high Strength from hydraulically hardened cement stone material as well a process for its manufacture.
  • SIMCON Slurry Infiltrated Mat Concrete
  • SIFCON Slurry Infiltrated Fiber Concrete
  • SIMCOM Standard Infiltrated Mat Concrete
  • a stainless steel fiber mat is first placed in a mold and then infiltrated with a cement-based slurry. These steel fiber mats are "pre-woven” and are supplied in large rolls. These mats only have to be cut and inserted into the mold. Because the orientation of the fibers in the fiber mat can be controlled, high tensile forces and ductility can be achieved with a relatively small fiber volume.
  • the cement mixtures for a SIMCON slurry have the following components in the proportions listed below: 1 / 0.31 / 0.6 / 0.3 / 0.045 Parts by weight of normal Portland cement / water / Quartz sand with a grain size of 250 mesh / Microsilica / super liquefier.
  • a fiber portion can be of 5.25% tensile strengths of 15.9 MPa at 1.1% elongation.
  • the SIMCON process provides for the concrete or the slurry mix and soak the stainless steel fiber mats with it, using vibration as an aid.
  • SIMCON mortars are e.g. Top layers Components or lost formwork created (ACI Structural Journal / September-October 1997, pp. 502-512). From SIMCON mortars but can only be relatively thick and flat components from minimal e.g. 15 to 20 mm are made because of the Steel fiber mats are relatively thick and completely potted the mats with flowable fresh mortar are relatively difficult is.
  • DT 24 09 231 A1 describes a process for the production of strengthened by inorganic binders and with mineral fibers reinforced spatial form bodies known.
  • a reinforced glue structure is known from DT 22 17 963.
  • the Reinforcement of the "glue structure", in particular a concrete, should be brought about by the fact that the reinforcement in particular Steel wool, steel fibers, steel rings and all other possible Elements with the concrete, for example, in a mixer or to be mixed in a mold.
  • the procedure corresponds according to this document the known SIFCON process, wherein but the reinforcement also made of plastic or glass material, Metal shavings or the like should be made.
  • the disadvantages corresponds to that of the SIFCON procedure, whereby Usually only particularly short fibers can be used in mixers are, otherwise there are layers, windings or Approaches to the mixing tools comes. You can also use this neither homogeneous distributions nor, according to that in the component introduced tensions, reinforcements in the Reach main stress directions
  • US 5,571,628 discloses metal fiber preforms and a method known for producing the same.
  • fibers with a length-to-diameter ratio of approx. 50 are introduced into a mold and, if necessary, in this mold a desired fiber content of, for example, 2 to 6% by volume be compressed.
  • the fibers by hand or with a Machine After the fibers by hand or with a Machine have been compressed, they are removed from the mold and passed as further pre-treatment steps as preforms, the further treatment steps provide that from the Infiltrate mold removed preform with a cement slurry.
  • a disadvantage of this method is that the preforms do not always maintain their shape and their compression strength and - after processing - their fiber content per Volumes are not reproducible.
  • preforms which have been produced in this way may possibly be reworked if they are in certain places, such as after molding, are expanded. Furthermore, in this Publication indicated that fiber contents above 10 vol .-% excluded are, because such high fiber contents are no longer infiltrable are.
  • the object of the invention is thin-walled, fiber-reinforced components high elasticity with a high fiber content and a very high dimensional stability and accuracy as well as a process to manufacture them with which not only thin-walled, flat, but also arbitrarily curved or angled shapes of thin components can be produced.
  • the invention provides to use steel wool mats, wherein these steel wool mats made of steel wool fibers of very small thickness and of great length. These steel wool fiber mats will strongly compressed according to the invention before infiltration. hereby fiber contents can be achieved that according to conventional Process and, according to conventional belief, not infiltrable are. According to the invention, these are pressed together in a mold Steel wool fiber mats with a specially selected cement suspension, namely a fine cement suspension with super plasticizers, injected.
  • the stainless steel wool is e.g. made from the material DIN 1.4113 or 1.4793 or alloyed stainless steels.
  • different Mats have fibers of different fineness; for example a mat is selected for components ⁇ 5 mm thick, which has an average fiber diameter of 0.08 mm; For Components with a greater thickness are suitable for coarser, medium fiber diameters from e.g. 0.12 mm.
  • the fiber lengths are between about 20 mm and several meters; average they several decimeters.
  • This long-fiber stainless steel wool is elastic and tough.
  • the fibers have length / diameter ratios (L / D ratios) of over 1000. Accordingly, this ratio is far above that critical value at which there is an increase in fiber length still property-improving effects.
  • the mats are very flexible or pliable, have a width of up to 1 m and are available rolled up on rolls with basis weights of, for example, 800 g / m 2 to 2000 g / m 2 .
  • the mats can be cut with scissors.
  • the stainless steel wool is preferably used with basis weights of 900 to 1000 g / m 2 and with average fiber diameters from 0.08 to 0.12 mm.
  • Fine cements are very fine-grained hydraulic binders, which by their chemical-mineralogical composition as well steady and graded grain distribution are characterized.
  • she generally consist of the usual cement raw materials, such as e.g. ground Portland cement clinker and / or ground slag sand and binding regulators; their production takes place in separate Production plants in cement plants.
  • Particularly advantageous is the individual grinding of the mineral raw materials that Separation of their fine components and their targeted composition also with regard to grain sizes and grain distribution.
  • Fine cements based on blastfurnace slag or Portland cement with a steady and graded particle size distribution with a maximum particle size d 95 of ⁇ 24 ⁇ m, preferably ⁇ 16 ⁇ m and an average particle size d 50 of ⁇ 7 ⁇ m, preferably ⁇ 5 ⁇ m are used. These are processed into suspensions by mixing them with water and with at least one so-called super liquefier (these are highly effective liquefiers or plasticizers), as well as in particular with microsilica and / or pigments and / or inert minerals, e.g. limestone powder and / or quartz powder and / or fly ash are mixed according to the same or less fineness as the fine cement.
  • super liquefier these are highly effective liquefiers or plasticizers
  • microsilica and / or pigments and / or inert minerals e.g. limestone powder and / or quartz powder and / or fly ash are mixed according to the same or less fineness as the fine cement.
  • Microsilica have very small grain diameters. It is in the range of about 0.1 ⁇ m. Because of this property, they are in able to fill the spaces between the cement grains. This will make the packing density in the cement paste matrix significantly increased. Although the grain diameter of the used Cement is moved in sizes of ⁇ 9.5 ⁇ m he is far surpassed by the microsilica particles, from what the filler effect results.
  • microsilica The pozzolanic properties of microsilica are shown in the Mainly determined by two properties. On the one hand they have a certain amount of reactive amorphous silicatic Ingredients that with the resulting calcium hydroxide during of cement hydration react. On the other hand, they have one large specific surface area on which these reactions take place can.
  • the effect of microsilica comes to improve the contact zone between surcharge and Cement stone matrix not to wear because the inventive Suspensions do not have a silicate additive.
  • microsilica is e.g. in amounts from 10 to 15 % By weight based on the solids content of the suspension in the form added to a dispersion consisting essentially of 50% by weight Microsilica and 50% by weight of water (slurry).
  • Fine cement based on blastfurnace slag is particularly advantageous for the suspensions used according to the invention because the very fine cements due to their lower reactivity towards fine cement based on Portland cement to achieve low viscosity Properties lower water levels and lower levels Liquefiers and / or superplasticizers are required.
  • Particularly suitable liquefiers or flow agents are e.g. the so-called super plasticizers such as lignin sulfonate, naphthalene sulfonate, Melamine sulfonate, polycarboxylate, which is considered highly effective Dispersing aids are known for the production of fine cement suspensions.
  • super plasticizers such as lignin sulfonate, naphthalene sulfonate, Melamine sulfonate, polycarboxylate, which is considered highly effective Dispersing aids are known for the production of fine cement suspensions.
  • the following mixtures are used in particular for the preparation of the suspensions used according to the invention: ultrafine 30 to 100, in particular 50 to 80% by mass; Condenser or Plasticizer (liquid) 0.1 to 5, in particular 0.5 to 4.0% by mass; Condenser or superplasticizer (Powder) 0.1 to 2.5, in particular 0.5 to 1.5% by mass; Microsilica (slurry) 0 to 30, in particular 5 to 15 mass%; pigments (Powder) 0 to 5, in particular 1 to 3% by mass; inert minerals 0 to 70, in particular 10 to 30% by mass; Feinstflugasche 0 to 50, in particular 10 to 30% by mass; each based on the solids content of the suspension.
  • the low-viscosity suspensions expediently have one Water / solids value between 0.4 and 0.6.
  • Your consistency, measured as the Marsh expiry time, is from 35 to 75 Seconds.
  • a suspension e.g. the amount of water required placed in a mixing vessel. Then the mixer is in Gear set and liquefier or eluent added. Subsequently the previously weighed dry substances are added. The mixture is then mixed further and homogenized in the process.
  • the components according to the invention are made according to a special embodiment the invention made by means of formwork.
  • the steel wool mats which are several millimeters thick, suitably to a desired thickness e.g. with the Formwork elements pressed together between the formwork.
  • the compression is due to the cotton-like Structure possible and causes a high degree of steel wool filling can be achieved.
  • one on top of the other Mats can be of any thickness e.g. also cross reinforcement will be realized.
  • the mats are pliable and pliable, they are almost unlimited adaptable and pressable to surface topographies. components or shapes can also be wrapped with it.
  • the mats with a fiber orientation according to the expected Voltage curve inserted in a mold or if necessary fixed to the existing component at certain points and by attaching it a formwork or the second half of the formwork with a corresponding one Contact pressure pressed to the desired thickness.
  • This procedure follows from Fig. 1.
  • the wool 1 is placed in a first formwork part 2 (process sequence a) and compressed with a second formwork part 3 (Arrow P, procedure b).
  • the degree of compression of the steel wool means that Degree of reinforcement (volume fraction of steel wool fibers) controlled.
  • Steel wool fibers are also present on the surface of the component are, especially in cases where the component exposed to aggressive media, stainless steel wool is used. It It is surprising that even the 10 to 20% of their delivery condition compressed steel wool mats completely and have it safely filled with fine binder suspensions. This is particularly astonishing because with fiber contents from around 6 Vol .-% the mats must be pressed together so strongly that there appears to be an impenetrable felt.
  • FIG. 2 Suspension 5 is pressed or injected from below against gravity into the edge-sealed formwork 2, 3 via an inlet 4 until the formwork is filled. The air can escape upwards through the outlet 6. After hardening of the suspension 5 to cement stone is removed.
  • the thin-walled component consists essentially of cement stone and several compressed mats 1 made of steel wool. It has unusually high strength, plastic deformation, working capacity, energy absorption until it reaches the fracture state and elasticity, which means that such thin components can be used as self-supporting building materials.
  • components with a thickness of less than 10 mm can be produced that have the following properties: thickness 4 to 8 mm flexural strength up to 80 N / mm 2 Compressive strength up to 70 N / mm 2 work capacity very high Tightness also against water very high
  • Such casings can optionally be mineral Insulation materials (e.g. foam concrete) can be filled and as highly effective Fire protection clothing serve. By appropriate shaping such plate, shell and molded parts can be used if necessary stiffen.
  • the material according to the invention can also be used as a cover layer e.g. for sandwich components.
  • sandwich components are fire protection doors.
  • the new building material also comes as an outer skin for reinforced concrete components into consideration, this skin being lost Formwork is used. Due to the factory production the thin-walled fiber material is also e.g. in column and Beam formwork a high degree of prefabrication achievable, with spacers already integrated for normal reinforcement could be.
  • a particular advantage is that such a lost one Formwork the post-treatment of the filled reinforced concrete makes dispensable, the tightness increases, thereby the rate of carbonation reduced and thus the corrosion protection improved for the reinforcing steel.
  • At factory made Formwork elements can be the quality of the surface control far more evenly and better than with in-situ concrete components. Coloring with expensive and complicated to use Pigments are limited to the few millimeters thick Outer skin. A good mechanical connection between the outer skin and filled reinforced concrete could be by pimples or suitable Structuring can be achieved on the inside.
  • the building material according to the invention also comes as a repair material into consideration. It can be found on damaged reinforced concrete surfaces complete top coats or local repairs be carried out. To do this, the imperfections and Cavities stuffed with steel wool mats, shelled, sealed and then injected. Cover layers can also be made after Principle of lost formwork applied and by injection be backfilled. Because of the low viscosity of the suspension and the fineness of the binder and due to the filling The formwork under pressure can be even the most complicated Mold surface structures. Therefore, the invention can also used for the production of reliefs and sculptures, which is particularly advantageous if the objects to be manufactured are exposed to particular mechanical stress.
  • the method according to the invention is independent of the orientation of the component applicable; therefore are in contrast to the SIMCON process e.g. also overhead applications e.g. on component undersides possible.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Panels For Use In Building Construction (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)

Abstract

The invention relates to a thin-walled component with a fine cement paste matrix and at least one steel wool mat that is pressed together and embedded in the fine cement paste matrix. The invention also relates to a method for producing a thin-walled component, whereby at least one steel wool mat is pressed together in a perpendicular position with respect to the main extension thereof, injected with a fine cement suspension, surrounded and the suspension is hardened.

Description

Die Erfindung betrifft ein dünnwandiges, flächiges Bauteil hoher Festigkeit aus hydraulisch erhärtetem Zementsteinmaterial sowie ein Verfahren zu seiner Herstellung.The invention relates to a thin-walled, flat component of high Strength from hydraulically hardened cement stone material as well a process for its manufacture.

Aus dem Artikel "Flexural Behavior of Composite R.C.-Slurry Infiltrated Mat Concrete (SIMCON) Members" (ACI Structural Journal, Technical Paper, Title no. 94-S46, September-October 1997) sind zwei Methoden der Faserverstärkung von Beton bekannt.From the article "Flexural Behavior of Composite R.C.-Slurry Infiltrated Mat Concrete (SIMCON) Members "(ACI Structural Journal, Technical Paper, Title no.94-S46, September-October 1997) two methods of fiber reinforcement of concrete are known.

Das eine Verfahren wird SIMCON (Slurry Infiltrated Mat Concrete) genannt, das anderer Verfahren SIFCON (Slurry Infiltrated Fiber Concrete). Bei dem SIMCOM-Verfahren wird zunächst eine Edelstahlfasermatte in eine Form eingelegt und dann mit einer auf Zement basierenden Schlämme infiltriert. Diese Stahlfasermatten sind "pre-woven" und werden in großen Rollen geliefert. Diese Matten müssen lediglich noch geschnitten und in die Form eingelegt werden. Dadurch, daß die Orientierung der Fasern in der Fasermatte kontrolliert werden kann, können hohe Zugkräfte und Duktilitäten bei relativ geringem Faservolumen erreicht werden. Die Zementmischungen für eine SIMCON-Schlämme weisen die folgenden Bestandteile in den nachfolgend aufgeführten Anteilen auf:
   1 / 0,31 / 0,6 / 0,3 / 0,045
   Gew.-Anteile von
   normalem Portlandzement / Wasser
   / Quarzsand einer Korngröße von 250 Mesh
   / Mikrosilica / Superverflüssiger.One process is called SIMCON (Slurry Infiltrated Mat Concrete), the other process SIFCON (Slurry Infiltrated Fiber Concrete). In the SIMCOM process, a stainless steel fiber mat is first placed in a mold and then infiltrated with a cement-based slurry. These steel fiber mats are "pre-woven" and are supplied in large rolls. These mats only have to be cut and inserted into the mold. Because the orientation of the fibers in the fiber mat can be controlled, high tensile forces and ductility can be achieved with a relatively small fiber volume. The cement mixtures for a SIMCON slurry have the following components in the proportions listed below:
1 / 0.31 / 0.6 / 0.3 / 0.045
Parts by weight of
normal Portland cement / water
/ Quartz sand with a grain size of 250 mesh
/ Microsilica / super liquefier.

Mit dem genannten Verfahren lassen sich bei einem Faseranteil von 5,25 % Zugfestigkeiten von 15,9 MPa bei 1,1 % Dehnung erreichen. Das SIMCON-Verfahren sieht vor, den Beton bzw. die Schlämme anzumischen und die Edelstahlfasermatten hiermit zu tränken, wobei Vibration zur Hilfe genommen wird.With the above-mentioned method, a fiber portion can be of 5.25% tensile strengths of 15.9 MPa at 1.1% elongation. The SIMCON process provides for the concrete or the slurry mix and soak the stainless steel fiber mats with it, using vibration as an aid.

Beim SIFCON-Verfahren werden die Fasern, und hierbei relativ kurze Fasern von lediglich 3 cm Länge, in einem vorgemischten Beton verteilt und anschließend mit diesem vergossen, was insbesondere bei Reparaturen von Vorteil sein soll. Die Nachteile von SIFCON werden in hohen Verarbeitungkosten und in fehlender gleicher Faserverteilung gesehen, so daß das SIFCON-Verfahren nicht sehr weit verbreitet ist.With the SIFCON process, the fibers become relative short fibers of only 3 cm in length, in a premixed Distributed concrete and then poured with it, which in particular should be advantageous for repairs. The disadvantages from SIFCON are in high processing costs and in lack seen the same fiber distribution, so the SIFCON process is not very common.

Nach der Erhärtung ist beim SIMCON-Verfahren ein stahlfaserbewehrter Festmörtel entstanden, der gegenüber einem unbewehrten Festmörtel eine erheblich höhere Duktilität und eine höhere Festigkeit bewirkende, günstigere Rißverteilung bei Überbelastung aufweist. Aus SIMCON-Mörteln werden z.B. Deckschichten auf Bauteilen oder verlorene Schalungen erzeugt (ACI Structural Journal/September-Oktober 1997, S. 502-512). Aus SIMCON-Mörteln können aber lediglich relativ dicke und ebenflächige Bauteile von minimal z.B. 15 bis 20 mm hergestellt werden, weil die Stahlfasermatten relativ dick sind und das vollständige Vergießen der Matten mit fließfähigem Frischmörtel relativ schwierig ist.After hardening, the SIMCON process is reinforced with steel fibers Solid mortar emerged, compared to an unreinforced Solid mortar a significantly higher ductility and a higher Strength-producing, more favorable crack distribution when overloaded having. SIMCON mortars are e.g. Top layers Components or lost formwork created (ACI Structural Journal / September-October 1997, pp. 502-512). From SIMCON mortars but can only be relatively thick and flat components from minimal e.g. 15 to 20 mm are made because of the Steel fiber mats are relatively thick and completely potted the mats with flowable fresh mortar are relatively difficult is.

Aus der DT 24 09 231 A1 ist ein Verfahren zur Herstellung von durch anorganische Bindemittel verfestigten und mit Mineralfasern verstärkten Raumform-Körpern bekannt.DT 24 09 231 A1 describes a process for the production of strengthened by inorganic binders and with mineral fibers reinforced spatial form bodies known.

Aus dieser Druckschrift ist es bekannt, durch anorganische Bindemittel verfestigte Massen mit Mineralfasern zu verstärken, wobei darauf hingewiesen wird, daß die Verstärkungsfasern i.A. durch Einmischen oder Einrieseln in die organischen Bindemittel eingebracht werden. Hierdurch würden jedoch nur unbefriedigende Ergebnisse erzielt. Demgegenüber sollen gemäß dieser Druckschrift flächige Verstärkungsmassen mit Bindemittelleim oder Mörtel getränkt werden und diese Verstärkungsmatten in frischem, nicht abgebundenem Zustand übereinander und/oder nebeneinander gelegt werden, bis die gewünschte Verstärkung erreicht ist. Beispielsweise soll eine flächige Verstärkungsmatte dadurch hergestellt werden, daß eine Verstärkungsmatte auf einem Tisch ausgerollt und pro Quadratmeter mit etwa 10 g Zementleim mit einem Wasserzementwert von 0,45 überzogen und mit einer Gummiwalze abgewalzt wird. Sodann wird die nächste Verstärkungsmatte aufgelegt und der Tränkvorgang wiederholt. Beim Aufeinanderlegen von 10 Verstärkungsmatten soll eine Platte von etwa 4 mm Dicke entstehen. Darüber hinaus schlägt diese Druckschrift vor, metallische Fasern mitzuverwenden. Bei einer Verstärkung gemäß dieser Druckschrift ist von Nachteil, daß sie besonders aufwendig ist und besonders geschultes Personal verlangt. Ferner entspricht dieses Verfahren in geradezu identischer Weise den üblicherweise eingesetzten Laminierverfahren für glasfaserverstärkte Kunststoffprodukte, welche ebenfalls den Nachteil eines großen Schmutzanfalls haben und zudem sehr aufwendig sind und eine anschließende Reinigungsprozedur erfordern. Zudem ist bei dem Verfahren gemäß dieser Druckschrift ein Mineralfasergehalt von 2 % üblich und möglich, der jedoch nicht ausreicht, um sehr starke Lasten abzufangen.From this publication it is known to use inorganic binders to strengthen solidified masses with mineral fibers, it should be noted that the reinforcing fibers i.A. by mixing or trickling into the organic binders be introduced. However, this would only make it unsatisfactory Results achieved. In contrast, according to this document flat reinforcing compounds with binder glue or Mortar and these reinforcement mats in fresh, unbound condition one above the other and / or side by side be placed until the desired gain is achieved. For example, a flat reinforcement mat is said to be thereby be made that a reinforcing mat on a table rolled out and with about 10 g of cement paste per square meter coated with a water cement value of 0.45 and with a rubber roller is rolled. Then the next reinforcement mat applied and the soaking process repeated. When laying on top of each other of 10 reinforcement mats should be a plate about 4 mm thick arise. In addition, this document suggests metallic Fibers to be used. With a reinforcement according to this Publication is disadvantageous in that it is particularly complex and specially trained personnel. Furthermore corresponds this procedure in an almost identical manner to the usual one laminating processes used for glass fiber reinforced plastic products, which also has the disadvantage of a big one Have dirt and are also very complex and one subsequent cleaning procedure. In addition, the Process according to this document a mineral fiber content of 2% common and possible, but not enough to be very intercept heavy loads.

Aus der DT 22 17 963 ist ein bewehrtes Leimgefüge bekannt. Die Bewehrung des "Leimgefüges", also insbesondere eines Betons, soll dadurch herbeigeführt werden, daß die Bewehrung insbesondere Stahlwolle, Stahlfasern, Stahlringe und alle anderen möglichen Elemente mit dem Beton beispielsweise in einem Mischer oder in einer Form gemischt werden. Insofern entspricht das Verfahren gemäß dieser Druckschrift dem bekannten SIFCON-Verfahren, wobei jedoch die Bewehrung auch aus Kunststoff oder Glaswerkstoff, Metallspänen oder ähnlichem hergestellt sein soll. Die Nachteile dieses Verfahrens entsprechen dem des SIFCON-Verfahrens, wobei üblicherweise in Mischern nur besonders kurze Fasern verwendbar sind, da es ansonsten zu Lagenbildungen, Wickelbildungen oder Ansätzen an den Mischwerkzeugen kommt. Zudem lassen sich hiermit weder homogene Verteilungen noch, entsprechend der in das Bauteil eingebrachten Spannungen, Verstärkungen in den Hauptspannungsrichtungen erreichen A reinforced glue structure is known from DT 22 17 963. The Reinforcement of the "glue structure", in particular a concrete, should be brought about by the fact that the reinforcement in particular Steel wool, steel fibers, steel rings and all other possible Elements with the concrete, for example, in a mixer or to be mixed in a mold. In this respect, the procedure corresponds according to this document the known SIFCON process, wherein but the reinforcement also made of plastic or glass material, Metal shavings or the like should be made. The disadvantages This procedure corresponds to that of the SIFCON procedure, whereby Usually only particularly short fibers can be used in mixers are, otherwise there are layers, windings or Approaches to the mixing tools comes. You can also use this neither homogeneous distributions nor, according to that in the component introduced tensions, reinforcements in the Reach main stress directions

Aus der US 5,571,628 sind Metallfaservorformlinge und ein Verfahren zur Herstellung derselben bekannt. Bei diesem Verfahren sollen Fasern mit einem Länge-zu-Durchmesser-Verhältnis von ca. 50 in eine Form eingebracht werden und in dieser Form ggf. auf einen gewünschten Fasergehalt von beispielsweise 2 bis 6 Vol.-% komprimiert werden. Nachdem die Fasern von Hand oder mit einer Maschine komprimiert wurden, werden sie aus der Form entfernt und als Vorformlinge weiteren Behandlungsschritten zugeführt, wobei die weiteren Behandlungsschritte vorsehen, den aus der Form entfernten Vorformling mit einer Zementschlämme zu infiltrieren. Bei diesem Verfahren ist von Nachteil, daß die Vorformlinge nicht immer ihre Form beibehalten und ihre Kompressionsstärke und - nach der Verarbeitung - auch ihr Fasergehalt pro Volumen nicht reproduzierbar sind. Darüber hinaus müssen Vorformlinge, die auf diese Art hergestellt wurden, evtl. nachbearbeitet werden, wenn sie an bestimmten Stellen, wie beispielsweise nach dem Ausformen, expandiert sind. Ferner wird in dieser Druckschrift angegeben, daß Fasergehalte über 10 Vol.-% ausgeschlossen sind, da derartig hohe Fasergehalte nicht mehr infiltrierbar sind.US 5,571,628 discloses metal fiber preforms and a method known for producing the same. With this procedure fibers with a length-to-diameter ratio of approx. 50 are introduced into a mold and, if necessary, in this mold a desired fiber content of, for example, 2 to 6% by volume be compressed. After the fibers by hand or with a Machine have been compressed, they are removed from the mold and passed as further pre-treatment steps as preforms, the further treatment steps provide that from the Infiltrate mold removed preform with a cement slurry. A disadvantage of this method is that the preforms do not always maintain their shape and their compression strength and - after processing - their fiber content per Volumes are not reproducible. In addition, preforms, which have been produced in this way may possibly be reworked if they are in certain places, such as after molding, are expanded. Furthermore, in this Publication indicated that fiber contents above 10 vol .-% excluded are, because such high fiber contents are no longer infiltrable are.

Aufgabe der Erfindung ist es, dünnwandige, faserverstärkte Bauteile hoher Elastizität mit einem hohen Fasergehalt und einer sehr hohen Dimensionsstabilität und Genauigkeit sowie ein Verfahren zu deren Herstellung zu schaffen, mit dem nicht nur dünnwandige, ebenflächige, sondern auch beliebig gekrümmte oder gewinkelte Formen dünner Bauteile herstellbar sind. Diese Aufgaben werden durch die Merkmale der Ansprüche 1 und 22 gelöst. Vorteilhafte Weiterbildungen der Erfindung werden in den von diesen Ansprüchen abhängigen Unteransprüchen gekennzeichnet.The object of the invention is thin-walled, fiber-reinforced components high elasticity with a high fiber content and a very high dimensional stability and accuracy as well as a process to manufacture them with which not only thin-walled, flat, but also arbitrarily curved or angled shapes of thin components can be produced. These tasks are solved by the features of claims 1 and 22. Advantageous developments of the invention are in the characterized dependent claims dependent claims.

Die Erfindung sieht vor, Stahlwollmatten zu verwenden, wobei diese Stahlwollmatten aus Stahlwollfasern sehr geringer Dicke und großer Länge bestehen. Diese Stahlwollfasermatten werden erfindungsgemäß vor dem Infiltrieren stark komprimiert. Hierdurch lassen sich Fasergehalte erzielen, die nach herkömmlichen Verfahren und nach herkömmlicher Überzeugung nicht infiltrierbar sind. Erfindungsgemäß werden diese in einer Form zusammengepreßten Stahlwollfasermatten mit einer speziell ausgewählten Zementsuspension, nämlich einer Feinstzementsuspension mit Superverflüssigern, injiziert.The invention provides to use steel wool mats, wherein these steel wool mats made of steel wool fibers of very small thickness and of great length. These steel wool fiber mats will strongly compressed according to the invention before infiltration. hereby fiber contents can be achieved that according to conventional Process and, according to conventional belief, not infiltrable are. According to the invention, these are pressed together in a mold Steel wool fiber mats with a specially selected cement suspension, namely a fine cement suspension with super plasticizers, injected.

Die Edelstahlwolle wird z.B. hergestellt aus dem Werkstoff DIN Nr. 1.4113 oder 1.4793 oder legierten Edelstählen. Unterschiedliche Matten weisen Fasern unterschiedlicher Feinheit auf; beispielsweise wird für Bauteile ≤ 5 mm Dicke eine Matte gewählt, die einen mittleren Faserdurchmesser von 0,08 mm aufweist; für Bauteile mit größerer Dicke eignen sich gröbere, mittlere Faserdurchmesser von z.B. 0,12 mm. Dabei liegen die Faserlängen zwischen etwa 20 mm und mehreren Metern; im Durchschnitt betragen sie mehrere Dezimeter.The stainless steel wool is e.g. made from the material DIN 1.4113 or 1.4793 or alloyed stainless steels. different Mats have fibers of different fineness; for example a mat is selected for components ≤ 5 mm thick, which has an average fiber diameter of 0.08 mm; For Components with a greater thickness are suitable for coarser, medium fiber diameters from e.g. 0.12 mm. The fiber lengths are between about 20 mm and several meters; average they several decimeters.

Diese langfaserige Edelstahlwolle ist elastisch und zäh. Die Fasern haben Längen/Durchmesser-Verhältnisse (L/D-Verhältnisse) von über 1000. Demgemäß liegt dieses Verhältnis weit über dem kritischen Wert, bei dem sich eine Zunahme der Faserlänge noch eigenschaftsverbessernd auswirkt.This long-fiber stainless steel wool is elastic and tough. The fibers have length / diameter ratios (L / D ratios) of over 1000. Accordingly, this ratio is far above that critical value at which there is an increase in fiber length still property-improving effects.

Die Matten sind sehr flexibel bzw. biegsam, weisen eine Breite bis zu 1 m auf und stehen mit Flächengewichten von z.B. 800 g/m2 bis 2000 g/m2 auf Rollen aufgerollt zur Verfügung. Die Matten sind mit einer Schere schneidbar.The mats are very flexible or pliable, have a width of up to 1 m and are available rolled up on rolls with basis weights of, for example, 800 g / m 2 to 2000 g / m 2 . The mats can be cut with scissors.

Im Rahmen der Erfindung wird die Edelstahlwolle vorzugsweise mit Flächengewichten von 900 bis 1000 g/m2 und mit mittleren Faserdurchmessern von 0,08 bis 0,12 mm verwendet.In the context of the invention, the stainless steel wool is preferably used with basis weights of 900 to 1000 g / m 2 and with average fiber diameters from 0.08 to 0.12 mm.

In Kombination mit dem ausgewählten und zusammengepreßten Stahlwollmattenerzeugnis in Form von Stahlwollefasern, insbesondere Edelstahlwolle, wird eine Suspension auf Basis von Feinstzement verwendet.In combination with the selected and compressed steel wool mat product in the form of steel wool fibers, in particular Stainless steel wool, is a suspension based on fine cement used.

Feinstzemente sind sehr feinkörnige hydraulische Bindemittel, die durch ihre chemisch-mineralogische Zusammensetzung sowie stetige und abgestufte Kornverteilung charakterisiert sind. Sie bestehen im allgemeinen aus den üblichen Zementrohstoffen, wie z.B. gemahlenem Portlandzementklinker und/oder gemahlenem Hüttensand und Abbindereglern; ihre Herstellung erfolgt in gesonderten Produktionsanlagen in Zementwerken. Besonders vorteilhaft ist die Einzelvermahlung der mineralischen Ausgangsstoffe, die Separation ihrer Feinstbestandteile und deren gezielte Zusammensetzung auch bezüglich der Korngrößen und Kornverteilung.Fine cements are very fine-grained hydraulic binders, which by their chemical-mineralogical composition as well steady and graded grain distribution are characterized. she generally consist of the usual cement raw materials, such as e.g. ground Portland cement clinker and / or ground slag sand and binding regulators; their production takes place in separate Production plants in cement plants. Particularly advantageous is the individual grinding of the mineral raw materials that Separation of their fine components and their targeted composition also with regard to grain sizes and grain distribution.

Das wesentliche Merkmal von Feinstzementen zur Abgrenzung gegenüber konventionellen Normzementen, z.B. nach DIN 1164, ist die vergleichsweise hohe Feinheit dieser Bindemittel bei gleichzeitiger Begrenzung ihres Größtkorns, das üblicherweise durch die Angabe des Korndurchmessers bei 95 Masse-% der Mischung d95 angegeben wird.The essential feature of fine cements to distinguish them from conventional standard cements, e.g. according to DIN 1164, is the comparatively high fineness of these binders with simultaneous limitation of their largest grain, which is usually specified by specifying the grain diameter for 95% by mass of the mixture d 95 .

Vorzügsweise werden Feinstzemente auf Hüttensand- oder Portlandzementbasis mit einer stetigen und abgestuften Kornverteilung mit einem Größtkorn d95 von ≤ 24 µm, vorzugsweise ≤ 16 µm, und einer mittleren Korngröße d50 von ≤ 7 µm, vorzugsweise ≤ 5 µm eingesetzt. Diese werden zu Suspensionen verarbeitet, indem sie mit Wasser und mit mindestens einem sogenannten Superverflüssiger (das sind hochwirksame Verflüssiger oder Fließmittel), sowie insbesondere auch mit Mikrosilica und/oder Pigmenten und/oder inerten Mineralstoffen, z.B. Kalksteinmehl und/oder Quarzmehl und/oder Flugasche entsprechend gleicher oder geringerer Feinheit wie der Feinstzement gemischt werden. Fine cements based on blastfurnace slag or Portland cement with a steady and graded particle size distribution with a maximum particle size d 95 of ≤ 24 µm, preferably ≤ 16 µm and an average particle size d 50 of ≤ 7 µm, preferably ≤ 5 µm are used. These are processed into suspensions by mixing them with water and with at least one so-called super liquefier (these are highly effective liquefiers or plasticizers), as well as in particular with microsilica and / or pigments and / or inert minerals, e.g. limestone powder and / or quartz powder and / or fly ash are mixed according to the same or less fineness as the fine cement.

Mikrosilica sind Produkte, die bei der Herstellung von Ferro-Silizium anfallen. Sie werden im allgemeinen in Form wäßriger Dispersionen als Zusatzstoff bei Hochleistungsbetonen eingesetzt. Diese Art der Mikrosilica ist bekannt unter dem Namen "Slurry". Im wesentlichen sind drei von einander unabhängige Wirkungen im Beton mit Silikatzusätzen zu unterscheiden:

  • Füllereffekt;
  • Puzzolanische Reaktionen;
  • Verbesserung der Kontaktzone zwischen Zuschlag und Zementstein;
    • Microsilica are products that are produced in the manufacture of ferro silicon. They are generally used in the form of aqueous dispersions as an additive in high-performance concrete. This type of microsilica is known as "slurry". There are essentially three independent effects in concrete with silicate additives:
  • Filler effect;
  • Pozzolanic reactions;
  • Improvement of the contact zone between aggregate and cement stone;

    • Mikrosilica haben sehr kleine Korndurchmesser. Er liegt im Bereich von.etwa 0,1 µm. Aufgrund dieser Eigenschaft sind sie in der Lage die Zwischenräume zwischen den Zementkörnern auszufüllen. Dadurch wird die Packungsdichte in der Zementsteinmatrix wesentlich erhöht. Obwohl sich der Korndurchmesser des verwendeten Zements schon in Größenordnungen von < 9,5 µm bewegt, wird er von den Mikrosilicapartikeln noch weit übertroffen, woraus der Füllereffekt resultiert.Microsilica have very small grain diameters. It is in the range of about 0.1 µm. Because of this property, they are in able to fill the spaces between the cement grains. This will make the packing density in the cement paste matrix significantly increased. Although the grain diameter of the used Cement is moved in sizes of <9.5 µm he is far surpassed by the microsilica particles, from what the filler effect results.

    Die puzzolanischen Eigenschaften der Mikrosilica werden in der Hauptsache von zwei Eigenschaften bestimmt. Zum einem besitzen sie einen gewissen Anteil an reaktiven amorphen silikatischen Bestandteilen, die mit dem entstehenden Calziumhydroxyd während der Zementhydratation reagieren. Zum anderen weisen sie eine große spezifische Oberfläche auf, an der diese Reaktionen stattfinden können.The pozzolanic properties of microsilica are shown in the Mainly determined by two properties. On the one hand they have a certain amount of reactive amorphous silicatic Ingredients that with the resulting calcium hydroxide during of cement hydration react. On the other hand, they have one large specific surface area on which these reactions take place can.

    Im Rahmen der vorliegenden Erfindung kommt die Wirkung der Mikrosilica zur Verbesserung der Kontaktzone zwischen Zuschlag und Zementsteinmatrix nicht zum Tragen, weil die erfindungsgemäßen Suspensionen keinen silikatischen Zuschlag aufweisen.In the context of the present invention, the effect of microsilica comes to improve the contact zone between surcharge and Cement stone matrix not to wear because the inventive Suspensions do not have a silicate additive.

    Erfindungsgemäß wird Mikrosilica z.B. in Mengen von 10 bis 15 Gew.-% bezogen auf den Feststoffanteil der Suspension in Form einer Dispersion zugegeben, die im wesentlichen aus 50 Gew.-% Mikrosilica und 50 Gew.% Wasser besteht (Slurry).According to the invention, microsilica is e.g. in amounts from 10 to 15 % By weight based on the solids content of the suspension in the form added to a dispersion consisting essentially of 50% by weight Microsilica and 50% by weight of water (slurry).

    Besonders vorteilhaft sind Feinstzemente auf Hüttensandbasis für die erfindungsgemäß verwendeten Suspensionen, weil die Feinstzemente aufgrund ihrer geringeren Reaktivität gegenüber Feinstzementen auf Portlandzementbasis zur Erzielung niedrigviskoser Eigenschaften geringere Wassergehalte und geringere Gehalte an Verflüssigern und/oder Fließmitteln erfordern.Fine cement based on blastfurnace slag is particularly advantageous for the suspensions used according to the invention because the very fine cements due to their lower reactivity towards fine cement based on Portland cement to achieve low viscosity Properties lower water levels and lower levels Liquefiers and / or superplasticizers are required.

    Besonders geeignete Verflüssiger bzw. Fließmittel sind z.B. die sogenannten Superverflüssiger wie Ligninsulfonat, Naphtalinsulfonat, Melaminsulfonat, Polycarboxylat, die als hochwirksame Dispergierhilfsmittel bekannt sind zur Herstellung von Feinstzementsuspensionen.Particularly suitable liquefiers or flow agents are e.g. the so-called super plasticizers such as lignin sulfonate, naphthalene sulfonate, Melamine sulfonate, polycarboxylate, which is considered highly effective Dispersing aids are known for the production of fine cement suspensions.

    Für die Herstellung der erfindungsgemäß verwendeten Suspensionen werden insbesondere folgende Mischungen verwendet: Feinstzement 30 bis 100, insbesondere 50 bis 80 Masse-%; Verflüssiger bzw.
    Fließmittel (flüssig)     0,1 bis 5, insbesondere 0,5 bis 4,0 Masse-%;     Verflüssiger bzw.
    Fließmittel
    (pulverförmig)     0,1 bis 2,5, insbesondere 0,5 bis 1,5 Masse-%;     Mikrosilica (Slurry) 0 bis 30, insbesondere 5 bis 15 Masse-%; Pigmente
    (pulverförmig)     0 bis 5, insbesondere 1 bis 3 Masse-%;     inerte Mineralstoffe 0 bis 70, insbesondere 10 bis 30 Masse-%; Feinstflugasche 0 bis 50, insbesondere 10 bis 30 Masse-%;     jeweils bezogen auf den Feststoffanteil der Suspension.    The following mixtures are used in particular for the preparation of the suspensions used according to the invention: ultrafine 30 to 100, in particular 50 to 80% by mass; Condenser or
    Plasticizer (liquid)     0.1 to 5, in particular 0.5 to 4.0% by mass;     Condenser or
    superplasticizer
    (Powder)     0.1 to 2.5, in particular 0.5 to 1.5% by mass;     Microsilica (slurry) 0 to 30, in particular 5 to 15 mass%; pigments
    (Powder)     0 to 5, in particular 1 to 3% by mass;     inert minerals 0 to 70, in particular 10 to 30% by mass; Feinstflugasche 0 to 50, in particular 10 to 30% by mass;     each based on the solids content of the suspension.

    Die niedrigviskosen Suspensionen weisen zweckmäßigerweise einen Wasser/Feststoffwert zwischen 0,4 und 0,6 auf. Ihre Konsistenz, gemessen als Auslaufzeit nach Marsh, beträgt von 35 bis 75 Sekunden.The low-viscosity suspensions expediently have one Water / solids value between 0.4 and 0.6. Your consistency, measured as the Marsh expiry time, is from 35 to 75 Seconds.

    Zur Herstellung einer Suspension wird z.B. die benötigte Wassermenge in einem Mischgefäß vorgelegt. Dann wird der Mischer in Gang gesetzt und Verflüssiger oder Fließmittel zugegeben. Anschließend erfolgt die Zugabe der zuvor abgewogenen Trockenstoffe. Danach wird die Mischung weitergemischt und dabei homogenisiert.For the preparation of a suspension e.g. the amount of water required placed in a mixing vessel. Then the mixer is in Gear set and liquefier or eluent added. Subsequently the previously weighed dry substances are added. The mixture is then mixed further and homogenized in the process.

    Die Erfindung wird im folgenden Beispiel anband einer Zeichnung erläutert. Es zeigen hierbei:

    Fig. 1a
    Stahlwollmatte in einer geöffneten Schalungsform,
    Fig. 1b
    Stahlwollmatte erfindungsgemäß zesammengepresst in einer geschlossenen Schalungsform,
    Fig. 2
    das erfindungsgemäße Injektionsverfabren in einer schematisierten Darstellung.
    The invention is explained in the following example on the basis of a drawing. They show:
    Fig. 1a
    Steel wool mat in an open formwork form,
    Fig. 1b
    Steel wool mat compressed according to the invention in a closed formwork form,
    Fig. 2
    the injection process according to the invention in a schematic representation.

    Die erfindungsgemäßen Bauteile werden nach einer besonderen Ausführungsform der Erfindung mittels Schalungen hergestellt. Dabei werden die Stahlwollmatten, die mehrere Millimeter dick sind, zweckmäßigerweise auf eine gewünschte Dicke z.B. mit den Schalungselementen zusammengepreßt zwischen den Schalungen angeordnet. Das Zusammenpressen ist aufgrund der watteartigen Struktur möglich und bewirkt, daß ein hoher Stahlwollefüllungsgrad erzielt werden kann. Durch mehrere, übereinander gelegte Matten kann eine beliebig dicke z.B. auch kreuzweise Bewehrung realisiert werden.The components according to the invention are made according to a special embodiment the invention made by means of formwork. there the steel wool mats, which are several millimeters thick, suitably to a desired thickness e.g. with the Formwork elements pressed together between the formwork. The compression is due to the cotton-like Structure possible and causes a high degree of steel wool filling can be achieved. Through several, one on top of the other Mats can be of any thickness e.g. also cross reinforcement will be realized.

    Da die Matten biegsam und schmiegsam sind, sind sie nahezu unbegrenzt an Oberflächentopographien anpaßbar und andrückbar. Bauteile oder Formen können damit auch umwickelt werden. Die Matten werden mit einer Faserorientierung entsprechend dem erwarteten Spannungsverlauf in eine Form eingelegt oder gegebenenfalls auf dem vorhandenen Bauteil punktuell fixiert und durch Anbringen einer Schalung bzw. der zweiten Schalungshälfte mit einem entsprechenden Anpreßdruck auf die gewünschte Dicke zusammengepreßt. Diese Verfahrensweise ergibt sich aus Fig. 1. Die Wolle 1 wird in ein erstes Schalungsformteil 2 eingebracht (Verfahrensablauf a) und mit einem zweiten Schalungsformteil 3 zusammengedrückt (Pfeil P, Verfahrensablauf b). Since the mats are pliable and pliable, they are almost unlimited adaptable and pressable to surface topographies. components or shapes can also be wrapped with it. The mats with a fiber orientation according to the expected Voltage curve inserted in a mold or if necessary fixed to the existing component at certain points and by attaching it a formwork or the second half of the formwork with a corresponding one Contact pressure pressed to the desired thickness. This procedure follows from Fig. 1. The wool 1 is placed in a first formwork part 2 (process sequence a) and compressed with a second formwork part 3 (Arrow P, procedure b).

    Durch den Grad des Zusammenpressens der Stahlwolle wird der Bewehrungsgrad (Volumenanteil der Stahlwollfasern) gesteuert. Da Stahlwollfasern auch an der Oberfläche des Bauteils vorhanden sind, wird insbesondere in den Fällen, in denen das Bauteil aggressiven Medien ausgesetzt ist, Edelstahlwolle verwendet. Es ist überraschend, daß sich sogar die auf 10 bis 20 % ihres Lieferzustandes zusammengedrückten Stahlwollmatten vollständig und sicher mit Feinstbindemittelsuspensionen verfüllen lassen. Dies ist besonders erstaunlich, weil bei Fasergehalten ab etwa 6 Vol.-% die Matten so stark zusammengepreßt werden müssen, daß sich ein scheinbar undurchdringlicher Filz ergibt.The degree of compression of the steel wool means that Degree of reinforcement (volume fraction of steel wool fibers) controlled. There Steel wool fibers are also present on the surface of the component are, especially in cases where the component exposed to aggressive media, stainless steel wool is used. It It is surprising that even the 10 to 20% of their delivery condition compressed steel wool mats completely and have it safely filled with fine binder suspensions. This is particularly astonishing because with fiber contents from around 6 Vol .-% the mats must be pressed together so strongly that there appears to be an impenetrable felt.

    Zur möglichst vollständigen und kontrollierten Ausfüllung der Hohlräume zwischen den Schalungsteilen werden die Schalungen randlich abgedichtet und die Suspension unter Druck in die die gepreßte Stahlwollmatte aufweisende Schalung eingebracht, wobei Luftaustrittslöcher vorgesehen sind, so daß die durch die Suspension in der Schalung verdrängte Luft entweichen kann.For the most complete and controlled filling of the Cavities between the formwork parts become the formwork sealed at the edge and the suspension under pressure in the pressed steel wool mat formwork introduced, wherein Air outlet holes are provided so that the through the suspension Air displaced in the formwork can escape.

    Dieses Verfahren wird beispielsweise und prinzipiell in Fig. 2 dargestellt. In die randlich abgedichtete Schalung 2,3 wird über einen Einlaß 4 von unten entgegen der Schwerkraft Suspension 5 eingedrückt bzw. injiziert, bis die Schalung ausgefüllt ist. Die Luft kann nach oben durch den Auslaß 6 entweichen. Nach dem Erhärten der Suspension 5 zu Zementstein wird entschalt. Das dünnwandige Bauteil besteht im wesentlichen aus Zementstein und mehreren zusammengepreßten Matten 1 aus Stahlwolle. Es weist ungewöhnlich hohe Festigkeiten, plastisches Verformungsvermögen, Arbeitsvermögen, Energieaufnahme bis zum Erreichen des Bruchzustandes und Elastizität auf, woraus resultiert, daß derartige dünne Bauteile als selbsttragendes Baumaterial verwendbar ist. Beispielsweise lassen sich Bauteile unter 10 mm Dicke herstellen, die die folgenden Eigenschaften aufweisen: Dicke 4 bis 8 mm Biegezugfestigkeit bis 80 N/mm2 Druckfestigkeit bis 70 N/mm2 Arbeitsvermögen sehr hoch Dichtigkeit auch gegen Wasser sehr hoch This method is shown, for example and in principle, in FIG. 2. Suspension 5 is pressed or injected from below against gravity into the edge-sealed formwork 2, 3 via an inlet 4 until the formwork is filled. The air can escape upwards through the outlet 6. After hardening of the suspension 5 to cement stone is removed. The thin-walled component consists essentially of cement stone and several compressed mats 1 made of steel wool. It has unusually high strength, plastic deformation, working capacity, energy absorption until it reaches the fracture state and elasticity, which means that such thin components can be used as self-supporting building materials. For example, components with a thickness of less than 10 mm can be produced that have the following properties: thickness 4 to 8 mm flexural strength up to 80 N / mm 2 Compressive strength up to 70 N / mm 2 work capacity very high Tightness also against water very high

    Es ist überraschend, daß nach dem erfindungsgemäßen Verfahren dünnwandige Bauteile herstellbar sind mit Suspensionen, die normalerweise keine hohen Biegezugfestigkeiten wegen des hohen Wasser/Zement-Verhältnisses erbringen. Es ist überraschend, daß nach dem erfindungsgemäßen Verfahren die vorgenannten Eigenschaften mit Suspensionen erzielt werden, die aufgrund ihres verleichsweise hohen Wasser/Zement-Verhältnisses normalerweise keine derartig hohen Biegezugfestigkeiten erwarten lassen. Mit SIMCON wird bei einem Stahlfasergehalt von ca. 6 Vol.-% und einem sehr geringen Wasserzementwert von < 0,4 nur etwa die Hälfte der oben genannten Biegezugfestigkeit erreicht. Aufgrund dieser überraschend hohen Festigkeit ist es möglich, dünnwandige selbsttragende Bauteile herzustellen.It is surprising that according to the method of the invention thin-walled components can be produced with suspensions that usually not high bending tensile strengths due to the high Provide water / cement ratio. It is surprising that the aforementioned properties by the process according to the invention can be achieved with suspensions due to their comparatively high water / cement ratio normally do not expect such high bending tensile strengths. With With a steel fiber content of approx. 6 vol.% And a very low water cement value of <0.4 only about Half of the above-mentioned bending tensile strength is reached. by virtue of this surprisingly high strength, it is possible to thin-walled to produce self-supporting components.

    Zudem ist überraschend, daß aufgrund des Injektionsverfahrens die dünnwandigen Bauteile an ihrer Oberfläche im wesentlichen aus Zementstein bestehen, während die Stahlwollfasern trotz des Anpreßdrucks der Schalung am fertigen Bauteil nur zu einem Bruchteil die Oberfläche tangieren.It is also surprising that due to the injection process the thin-walled components on their surface essentially consist of cement stone, while the steel wool fibers despite the Contact pressure of the formwork on the finished component only to one Fraction affect the surface.

    Nach dem erfindungsgemäßen Verfahren lassen sich verschiedenartige zementgebundene Formteile herstellen, die sehr dünnwandig sowie hochbewehrt sind und die darüberhinaus nahezu beliebig geformt und gegebenenfalls an der Oberfläche beliebig strukturiert werden können. Anwendungsbeispiele sind:

  • Platten;
  • Schalen;
  • Rohre und
  • Formteile mit nahezu beliebigen Querschnitten;
    • die als Dach- und Fassadenbekleidungen sowie zur Ummantelung oder Bekleidung zu schützender oder zu verdeckender Bauteile eingesetzt werden können.The method according to the invention can be used to produce various types of cement-bound molded parts which are very thin-walled and highly reinforced and which, moreover, can be shaped almost as desired and, if necessary, can be structured as desired on the surface. Application examples are:
  • Plates;
  • Peel;
  • Pipes and
  • Molded parts with almost any cross-section;
    • that can be used as roof and facade cladding as well as for sheathing or cladding of components to be protected or concealed.

    Derartige Ummantelungen können gegebenenfalls mit mineralischen Dämmmaterialien (z.B. Schaumbeton) gefüllt werden und als hochwirksame Brandschutzbekleidung dienen. Durch entsprechende Formgebung lassen sich solche Platten-, Schalen- und Formteile erforderlichenfalls aussteifen. Um ein hohes Maß an Vorfertigung und einen hohen Rationalisierungsgrad auf der Baustelle zu erreichen, können im Fertigteilwerk hergestellte Halbschalen in ähnlicher Weise wie Kabelkanäle aus Kunststoff über die zu ummantelnden Rohre oder Stahl-, Holz- und Kunststoffbauteile gestülpt und anschließend zusammengefügt werden. Die Stoßfugen lassen sich mit handelsüblichen Materialien abdichten und die Hohlräume über Einfüllstutzen mit Isoliermaterial füllen.Such casings can optionally be mineral Insulation materials (e.g. foam concrete) can be filled and as highly effective Fire protection clothing serve. By appropriate shaping such plate, shell and molded parts can be used if necessary stiffen. To a high degree of prefabrication and to achieve a high degree of rationalization on the construction site, can half shells manufactured in the precast plant in Similar to plastic cable ducts over the ones to be sheathed Pipes or steel, wood and plastic components turned over and then put together. The butt joints can be sealed with commercially available materials and the Fill cavities over the filler neck with insulating material.

    Wegen der nahezu beliebigen Farb- und Formgebung sowie Oberflächenstrukturierung, insbesondere wegen der hohen Wasserdichtigkeit und der hervorragenden mechanischen Eigenschaften bietet sich der Werkstoff gemäß der Erfindung auch als Deckschicht z.B. für Sandwich-Bauteile an. Ein Beispiel für solche neuartigen Sandwich-Bauteile sind Feuerschutztüren. Aus den gleichen Gründen kommt das neue Baumaterial auch als Außenhaut für Stahlbetonbauteile in Betracht, wobei diese Außenhaut als verlorene Schalung verwendet wird. Aufgrund der werksmäßigen Herstellung des dünnwandigen Faserwerkstoffs ist auch z.B. bei Stützen- und Balkenschalungen ein hoher Grad der Vorfertigung erreichbar, wobei bereits Abstandhalter für die normale Bewehrung integriert sein können. Ein besonderer Vorteil ist, daß eine solche verlorene Schalung die Nachbehandlung des eingefüllten Stahlbetons entbehrlich macht, die Dichtigkeit erhöht, dadurch die Carbonatisierungsgeschwindigkeit herabsetzt und somit den Korrosionsschutz für den Bewehrungsstahl verbessert. Bei werksmäßig herstellten Schalelementen läßt sich die Qualität der Oberfläche weit gleichmäßiger und besser steuern als bei Ortbetonbauteilen. Das Einfärben mit teueren und in der Anwendung komplizierten Pigmenten beschränkt sich allein auf die wenige millimeterdicke Außenhaut. Eine gute mechanische Verbindung zwischen Außenhaut und eingefülltem Stahlbeton könnte durch Noppen oder geeignete Strukturierung auf der Innenseite erreicht werden.Because of the almost any color and shape as well as surface structuring, especially because of the high water resistance and which offers excellent mechanical properties the material according to the invention can also be used as a cover layer e.g. for sandwich components. An example of such new types Sandwich components are fire protection doors. For the same reasons the new building material also comes as an outer skin for reinforced concrete components into consideration, this skin being lost Formwork is used. Due to the factory production the thin-walled fiber material is also e.g. in column and Beam formwork a high degree of prefabrication achievable, with spacers already integrated for normal reinforcement could be. A particular advantage is that such a lost one Formwork the post-treatment of the filled reinforced concrete makes dispensable, the tightness increases, thereby the rate of carbonation reduced and thus the corrosion protection improved for the reinforcing steel. At factory made Formwork elements can be the quality of the surface control far more evenly and better than with in-situ concrete components. Coloring with expensive and complicated to use Pigments are limited to the few millimeters thick Outer skin. A good mechanical connection between the outer skin and filled reinforced concrete could be by pimples or suitable Structuring can be achieved on the inside.

    Das erfindungsgemäße Baumaterial kommt auch als Instandssetzungsmaterial in Betracht. Es können an geschädigten Stahlbetonoberflächen komplette Deckbeschichtungen oder örtliche Ausbesserungen ausgeführt werden. Dazu werden die Fehlstellen und Hohlräume mit Stahlwollmatten ausgestopft, geschalt, abgedichtet und anschließend injiziert. Deckschichten können auch nach dem Prinzip verlorener Schalung aufgebracht und durch Injektion hinterfüllt werden. Aufgrund der niedrigen Viskosität der Suspension und der Feinheit des Bindemittels und aufgrund der Füllung der Schalung unter Druck lassen sich auch komplizierteste Oberflächenstrukturen abformen. Daher kann die Erfindung auch für die Herstellung von Reliefs und Skulpturen benutzt werden, was von besonderem Vorteil ist, wenn die herzustellenden Objekte besonderer mechanischer Beanspruchung ausgesetzt sind.The building material according to the invention also comes as a repair material into consideration. It can be found on damaged reinforced concrete surfaces complete top coats or local repairs be carried out. To do this, the imperfections and Cavities stuffed with steel wool mats, shelled, sealed and then injected. Cover layers can also be made after Principle of lost formwork applied and by injection be backfilled. Because of the low viscosity of the suspension and the fineness of the binder and due to the filling The formwork under pressure can be even the most complicated Mold surface structures. Therefore, the invention can also used for the production of reliefs and sculptures, which is particularly advantageous if the objects to be manufactured are exposed to particular mechanical stress.

    Das erfindungsgemäße Verfahren ist unabhängig von der Orientirung des Bauteils anwendbar; daher sind im Gegensatz zum SIMCON-Verfahren z.B. auch Anwendungen über Kopf z.B. an Bauteilunterseiten möglich.The method according to the invention is independent of the orientation of the component applicable; therefore are in contrast to the SIMCON process e.g. also overhead applications e.g. on component undersides possible.

    Durch das Zusammendrücken der Stahlwollematten wird offensichtlich ein neues Produkt geschaffen, das für die Zwecke der Erfindung erst dadurch verwendbar wird. In Kombination mit den Suspensionen auf Feinstzementbasis kann die zusammengepreßte Struktur der Stahlwolle derart in Wirkverbindung mit dem erhärteten Suspensionsmaterial treten, daß ein neues Bauteil mit unerwarteten Eigenschaften entsteht.The compression of the steel wool mats becomes obvious created a new product for the purposes of the invention only then can it be used. In combination with the suspensions on the basis of fine cement, the compressed structure the steel wool in operative connection with the hardened Suspension material occurs that a new component with unexpected Properties arises.

    Claims (54)

    1. Fibre-reinforced, thin-walled component comprising metal fibres and a cement matrix, characterized in that the cement matrix comprises a superfine cement matrix (5) formed from superfine cement and highly effective fluidizers, and a plurality of superposed, compressed steel wool mats (1) are present in the superfine cement matrix (5), with the outer surfaces of the component being virtually free of steel wool fibres.
    2. Component according to Claim 1, characterized in that the main surfaces of the component are smooth and essentially superfine cement material is present on the surfaces.
    3. Component according to Claim 2, characterized in that the steel wool mats (1) are arranged so that the main directions of the steel wool fibres of the steel wool mats cross.
    4. Component according to any of Claims 1 to 3, characterized by a content of steel wool mats of from 2 to 10% by volume, in particular from 4 to 8% by volume.
    5. Component according to any of Claims 1 to 4, characterized by a thickness of from 3 to 10 mm, in particular from 4 to 8 mm.
    6. Component according to any of Claims 1 to 5, characterized by a bending tensile strength of from 25 to 80 N/mm2, in particular from 50 to 75 N/mm2.
    7. Component according to any of Claims 1 to 6, characterized by a compressive strength of from 30 to 75 N/mm2, in particular from 45 to 60 N/mm2.
    8. Component according to any of Claims 1 to 7, characterized in that the component is coloured by means of pigments.
    9. Component according to any of Claims 1 to 8, characterized in that the component has a curved shape.
    10. Component according to any of Claims 1 to 9, characterized in that the component has a shuttering structure on its main surfaces.
    11. Component according to any of Claims 1 to 10, characterized in that the steel wool fibres of the steel wool mats (1) have a mean fibre diameter of from 0.05 to 0.20 mm, in particular from 0.08 to 0.12 mm.
    12. Component according to any of Claims 1 to 11, characterized in that the steel wool mats (1) have a weight per unit area of from 600 to 2000 g/m2, in particular from 700 to 1100 g/m2.
    13. Component according to any of Claims 1 to 12, characterized in that the steel wool fibres have a length/diameter ratio of over 1000.
    14. Component according to any of Claims 1 to 13, characterized in that the superfine cement matrix (5) comprises microsilica in amounts of from 0 to 30% by mass, in particular from 5 to 15% by mass.
    15. Component according to any of Claims 1 to 14, characterized in that the superfine cement matrix (5) comprises pigments in amounts of from 0 to 5% by mass, in particular from 1 to 3% by mass.
    16. Component according to any of Claims 1 to 15, characterized in that the superfine cement matrix (5) comprises inert mineral materials in amounts of from 0 to 70% by mass, in particular from 10 to 30% by mass.
    17. Component according to any of Claims 1 to 16, characterized in that the superfine cement matrix (5) comprises quartz flour in amounts of from 0 to 70% by mass, in particular from 10 to 30% by mass.
    18. Component according to any of Claims 1 to 17, characterized in that the superfine cement matrix (5) comprises superfine fly ash in amounts of from 0 to 50, in particular from 0 to 30% by mass.
    19. Component according to any of Claims 1 to 18, characterized in that the superfine cement matrix (5) is a portland cement matrix.
    20. Component according to any of Claims 1 to 19, characterized in that the superfine cement matrix is a slag cement matrix.
    21. Component according to any of Claims 1 to 20, characterized in that the compressed steel wool mats are from 3 to 10 mm thick, in particular from 4 to 8 mm thick.
    22. Process for producing a thin-walled component reinforced with metal fibres, comprising a cement matrix and steel fibres, in particular a component according to one or more of Claims 1 to 21, characterized in that to form a thin wall a plurality of steel wool mats (1) are superposed and compressed perpendicular to their respective main elongation in shuttering (2, 3) and, after compression, a suspension (5) comprising superfine cement and a highly effective fluidizer is injected into the shuttering (2, 3) and the steel wool mats (1), the suspension (5) is subsequently allowed to cure and the component is then removed from the shuttering mould (2, 3).
    23. Process according to Claim 22, characterized in that stainless steel wool mats (1) are used.
    24. Process according to Claim 22 or 23, characterized in that steel wool mats (1) in which the steel wool fibres have mean fibre diameters of from 0.05 to 0.20 mm, in particular from 0.08 to 0.12 mm, are used.
    25. Process according to any of Claims 22 to 24, characterized in that steel wool mats (1) in which the fibre lengths are from 20 mm to a plurality of metres, on average a plurality of decimetres, are used.
    26. Process according to any of Claims 22 to 25, characterized in that steel wool mats (1) whose fibres have a length/diameter ratio of over 1000 are used.
    27. Process according to any of Claims 22 to 26, characterized in that steel wool mats (1) having a weight per unit area of from 600 to 2000 g/m2, in particular from 700 to 1100 g/m2, are used.
    28. Process according to any of Claims 22 to 27, characterized in that the steel wool mats (1) are compressed by from 10 to 20% of their thickness.
    29. Process according to any of Claims 22 to 28, characterized in that two steel wool mats (1) are used and the main direction of the fibres of one steel wool mat (1) is at an angle to the main direction of the fibres of the other steel wool mat (1).
    30. Process according to any of Claims 22 to 29, characterized in that a superfine cement suspension (5) based on slag sand and activators is used.
    31. Process according to any of Claims 22 to 30, characterized in that a suspension (5) based on superfine cement on the basis of portland cement is used.
    32. Process according to any of Claims 22 to 31, characterized in that a superfine cement having a gradated particle size distribution and a d95 of ≤ 24 µm, preferably ≤ 16 µm, is used for producing the superfine cement suspension (5).
    33. Process according to Claim 32, characterized in that a superfine cement having a mean particle size d50 of ≤ 7 µm, in particular ≤ 5 µm, is used.
    34. Process according to Claim 33, characterized in that microsilica, particularly in the form of a dispersion, is mixed in.
    35. Process according to Claim 33 or 34, characterized in that a pigment is mixed in.
    36. Process according to any of Claims 33 to 35, characterized in that a mineral material having the same fineness as or a greater fineness than the superfine cements is mixed in.
    37. Process according to any of Claims 33 to 36, characterized in that naphthalenesulphonate is used as highly effective fluidizer.
    38. Process according to any of Claims 33 to 37, characterized in that a polycarboxylate is used as superfluidizer.
    39. Process according to any of Claims 22 to 38, characterized in that the following compositions are used for producing the suspension (5) based on superfine cement: Superfine cement From 30 to 100% by mass, in particular from 50 to 80% by mass; Fluidizer or flow
      improver (liquid)       from 0.1 to 5% by mass, in particular from 0.5 to 4.0% by mass;       Fluidizer or flow
      improver
      (pulverulent)       from 0.1 to 2.5% by mass, improver in particular from 0.5 to 1.5% by mass;       Microsilica (slurry) from 0 to 30% by mass, in particular from 5 to 15% by mass; Pigments
      (pulverulent)       from 0 to 5% by mass, in particular from 1 to 3% by mass;       Inert mineral materials from 0 to 70% by mass, in particular from 10 to 30% by mass; Superfine fly ash from 0 to 50% by mass, in particular from 10 to 30% by mass;
      based on the solids content of the suspension.
    40. Process according to any of Claims 22 to 39, characterized in that suspensions (5) having a water/solids ratio of from 0.4 to 0.6 are used.
    41. Process according to any of Claims 22 to 40, characterized in that suspensions (5) having a consistency, measured as the Marsh outflow time, of from 35 to 75 seconds are used.
    42. Process according to any of Claims 22 to 41, characterized in that the suspensions (5) are produced by placing the amount of water required in a mixing vessel and adding the fluidizer or flow improver while mixing, then adding the previously weighed out dry materials and continuing to mix and thus homogenize the mixture.
    43. Process according to any of Claims 22 to 42, characterized in that the steel wool mats (1) are compressed between sealed shuttering (2, 3) and the superfine cement suspension (5) is injected under pressure into the shuttering (2, 3), with an air outlet (6) being provided so that the air can escape from the space within the shuttering during injection.
    44. Process according to Claim 43, characterized in that injection is carried out in a direction opposite to that of gravity.
    45. Process according to any of Claims 22 to 44, in particular according to Claim 44 or 45, characterized in that components having a thickness of ≤ 10 mm are produced.
    46. Use of a component according to any of Claims 1 to 21 and produced according to one or more of Claims 22 to 43 as roof and/or exterior wall and/or wall cladding.
    47. Use of a component according to any of Claims 1 to 21 and produced according to any of Claims 22 to 43 as sheathing or cladding for components to be protected or to be covered.
    48. Use of a component according to any of Claims 1 to 21 and produced according to any of Claims 22 to 43 in the form of half shells for producing and sheathing channels, pipes or the like.
    49. Use of a component according to any of Claims 1 to 21 and produced according to any of Claims 22 to 43 as a sandwich element for producing fire doors.
    50. Use of a component according to any of Claims 1 to 21 and produced according to any of Claims 22 to 43 as external skin for steel-reinforced concrete components.
    51. Use according to Claim 50, characterized in that the external skin is lost shuttering.
    52. Use of a component according to any of Claims 1 to 21 and produced according to any of Claims 22 to 43 as lost shuttering.
    53. Use of a component according to any of Claims 1 to 21 and produced according to any of Claims 22 to 43 as repair material, wherein faulty areas and/or hollows in damaged concrete surfaces are stuffed with at least one steel wool mat, the mat is compressed and subsequently shuttered, sealed and the suspension is injected.
    54. Use of a component according to any of Claims 1 to 21 and produced according to any of Claims 22 to 43 for moulding complicated surface structures.
    EP99970707A 1998-10-20 1999-09-15 Thin-walled component made from hydraulically hardened cement paste material and method for the production thereof Expired - Lifetime EP1141497B1 (en)

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    DE19848248A DE19848248C2 (en) 1998-10-20 1998-10-20 Thin-walled component made of hydraulically hardened cement stone material and process for its production
    DE19848248 1998-10-20
    PCT/EP1999/006821 WO2000023671A1 (en) 1998-10-20 1999-09-15 Thin-walled component made from hydraulically hardened cement paste material and method for the production thereof

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    NO20011621L (en) 2001-06-18
    NO20011621D0 (en) 2001-03-30
    DE19848248A1 (en) 2000-05-18
    WO2000023671A1 (en) 2000-04-27
    DE59904888D1 (en) 2003-05-08
    EP1141497A1 (en) 2001-10-10
    SK5342001A3 (en) 2001-12-03
    ZA200103041B (en) 2002-01-23
    HUP0103879A3 (en) 2002-02-28
    BR9914712A (en) 2001-07-31
    TR200101110T2 (en) 2001-12-21
    HK1038777A1 (en) 2002-03-28
    CN1324426A (en) 2001-11-28
    ATE236313T1 (en) 2003-04-15
    US6797370B1 (en) 2004-09-28
    ES2193785T3 (en) 2003-11-01
    HUP0103879A2 (en) 2002-01-28
    PL347332A1 (en) 2002-03-25
    CZ20011415A3 (en) 2002-02-13
    DE19848248C2 (en) 2001-08-30

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