EP1805114A2

EP1805114A2 - Lightweight concrete

Info

Publication number: EP1805114A2
Application number: EP05790162A
Authority: EP
Inventors: Klaus Dvorak
Original assignee: "TECHNOPOR" Handels GmbH
Current assignee: EXXAG INVESTMENTS Ltd
Priority date: 2004-10-07
Filing date: 2005-10-07
Publication date: 2007-07-11
Also published as: AT501684B9; WO2006037144A2; AT501684B1; WO2006037144A3; AT501684A1

Abstract

The invention relates to lightweight concrete comprising granular glass foam having at least one grain size fraction with a binder, preferably cement, asphalt, or synthetic resin. The granular glass foam is provided with a grain size fraction of at least 2, preferably at least 4. A filler material having a grain size fraction of up to 4, preferably up to 2, and a concentration of 0.1 to 50 percent, preferably 0.1 to 25 percent by volume relative to the lightweight concrete is provided as a moiety of fine material. Blown glass balls, preferably with a sintered surface, can be used as a filler material, for example.

Description

lightweight concrete

The invention relates to a lightweight concrete, which consists of glass foam granules at least one grain fraction with a binder, preferably cement, bitumen or synthetic resin. Furthermore, the invention also relates to a method for producing lightweight concrete.

From EP 1 044 938 A1 it is known to use broken foam glass as an additive for a flowable casting compound bound with a binder. The aggregates should have a fuller curve approximated sieve curve. The disadvantage here is that to achieve the grain sizes of the aggregates according to a fuller curve consuming operations, such as mechanical crushing, are necessary.

The definition of Fuller curve is generally state of the art and can be found in the relevant literature and the corresponding standards.

The use of a monocome of broken foam glass chunks as an aggregate for lightweight concrete is also known from EP 0 012 1 14 A and from JP 10 203836 A.

Furthermore, it is known from EP 0 292 424 A1 to produce foam bodies from glass powder and a special activator.

A disadvantage of the above-mentioned lightweight concrete types and their production is mainly the production of fine fraction, since this must be carried out with complex mechanical processes. Another serious disadvantage is the fact that in the production of fine fraction heavy environmental pollution can be avoided only by the most expensive precautions. It is therefore an object of the invention to provide a lightweight concrete of the type cited, which on the one hand avoids the above disadvantages and on the other hand can be produced efficiently and economically.

The object is achieved by the invention.

The lightweight concrete according to the invention is characterized in that the glass foam granules have a grain fraction at least the size 2, preferably at least the size 4, and that as fine fraction, a filler material having a grain fraction to 4, preferably to 2, and a volume fraction of

Lightweight concrete from 0.1 to 50%, preferably from 0.1 to 25%. With the lightweight concrete according to the invention, it is now possible to produce a building material for optimal economic aspects, which also meets the corresponding requirements, be it the relevant standards or other legal provisions, with certainty. Thus, prefabricated elements, such as lightweight components, monolithic walls or structural concrete, but also bricks, in particular hollow bricks, attachment elements, soundproofing elements or ready-mixed concrete or in-situ concrete can be produced from the lightweight concrete according to the invention. The lightweight concrete according to the invention for the various applications is made of glass foam granules, according to the required grain size and Komgefüges and a binder or a filler material for the desired properties.

The serious advantage of this lightweight concrete according to the invention is to be seen in the fact that deliberately no fines are produced during the production of the glass foam granules. As a result, an environmental impact, including the machinery, by dust is not given. Furthermore, by avoiding the fine fraction no breaking technique is needed, which comes in the field of milling. These normally mandatory operations are eliminated. A more rational production method is thereby ensured.

As filler material for the lightweight concrete according to the invention in particular a commercially available, commercially available product is used. According to the Requirements for the lightweight concrete according to the invention is selected in the filler material palette. Corresponding examples are given below.

According to a special feature of the invention, a maximum of two

Grain fractions of the glass foam granules used. As a result, the lightweight concrete produced in this way can be produced with economic outlay in accordance with its intended use.

According to a further feature of the invention, the proportion of glass foam granules is a maximum of 75%. As a result, not only the corresponding standard values are achieved, but the physical impression of conventional concrete, in particular lightweight concrete, caused increased.

According to a special feature of the invention are used as filler material

Organic glass spheres, preferably with a sintered surface used. Such a filler material has a lower weight than the fine fraction of the glass foam granules, whereby an extremely lightweight concrete is produced.

According to a further embodiment, expanded clay sand is used as filler material. By using this filler material, the compressive strength of the lightweight concrete according to the invention thus produced is increased. In addition, the use of expanded clay sand allows moisture storage in lightweight concrete.

According to a further particular embodiment of the invention pumice is used as filler material. This naturally occurring filler material blends seamlessly into today's trend-setting bio-philosophy of living and also allows in combination with glass foam granules good thermal insulation and sufficient compressive strength.

According to an alternative embodiment of the invention, natural sand or fly ash is used as filler material. This filler material is also trendy the bio-philosophy and has the high specific gravity high compressive strength of lightweight concrete.

According to a further alternative embodiment of the invention, the filler material used is preferably comminuted, expanded and / or extruded polystyrene. As a result, a very lightweight and highly insulating lightweight concrete is produced.

According to a further alternative embodiment of the invention, perlites are used as the filler material. This filler material is not only very light, but its characteristics are a compromise between expanded clay sand and blown glass beads.

According to a further alternative embodiment of the invention, hemp fibers are used as filler material. Hemp fibers serve as a reinforcement, similar to a reinforcement, and increase the flexural and compressive strength. At the same time, the hemp fibers serve as insulation additives. In addition, they serve for water storage and moisture buffering, so that a particularly favorable living climate is achieved. Hemp is also one of the few natural fibers that are resistant to microbial attack and very much in line with today's ecological trend. As a secondary effect for hemp fibers, it can be seen that the cultivation of this natural product promotes agriculture and in the course of its growth stores three times as much nitrogen oxides as conventional plants. This fertilization of the soil for subsequent plants is practically no longer necessary.

According to a particular feature of the invention, the lightweight concrete has a closed grain structure. A lightweight concrete with a closed Komgefüge is needed especially in the production of monolithic walls. Of course, such a lightweight concrete can also be used for precast parts of any kind or construction elements, for example, scarf protection elements. According to one embodiment of the invention, an air entraining agent is added. As a result, a lightweight concrete can be produced economically, which is light and yet has a completely closed surface.

According to a further special feature of the invention, the lightweight concrete has an open or heap-porous Komgefüge. Such lightweight concrete is used primarily in the production of bricks, especially hollow bricks, use.

According to one embodiment of the invention, the lightweight concrete is a

Foaming agent added. This foaming agent fills the cavities between the individual glass foam granules. Since the specific gravity of this foaming agent is far below the specific weight of a glass foam granulate fine fraction, an extremely lightweight concrete is achieved. In addition, both very high static requirements, as well as very high heat-insulating parts, even in exposed concrete quality, can be realized cost-effectively.

According to a further alternative embodiment, a starch ether is added to the lightweight concrete. With the addition of such a starch ether in the dosage of, for example, 0.025 to 0.5% by weight of the binder, for example cement, in particular segregation during processing is avoided. This is particularly advantageous when processing masses with different grain densities, such as glass foam granules and polystyrene or sand. The starch ether acts like an adhesive, which glides past the individual grains and thus prevents segregation. The

The problem that the filler material with particle sizes below 4, in particular below 2, tend to go down in the mixture and the grain fractions above 4 strongly float, can be avoided.

However, the object of the invention is also to provide an extremely economical process for the production of lightweight concrete. The inventive method is characterized in that the glass foam granules exclusively from a mixture of Glasmeh! and silicon carbide is prepared, wherein in a conventional manner, the glass powder and the silicon carbide are dry mixed and the mixture is subsequently blown in a thermal process. With this method according to the invention it is now possible to produce lightweight concrete, which meets both the standard and the legal requirements and which can also be generated efficiently and therefore the economic aspects accommodating.

According to a particular feature of the invention, the glass foam sheets produced in the thermal process are treated shock-like immediately after the thermal process with a gaseous or liquid coolant. The targeted use of the coolant, be it air, water or steam, for example, can directly influence the breaking of the material leaving the blast furnace. In this case, the hot material with the coolant, for example in the form of a jet or flat, treated. With an optimized use of coolant, the desired particle size of the refracting glass foam granules can be achieved by far.

According to a further embodiment of the invention, the glass foam plates produced in the thermal process are comminuted with a mechanical device, for example a spiked roller with cutting tools. In this case, the spiked roller arranged directly or near the furnace outlet could move at the circumferential speed of the material ejection. By "cutting" or "cutting" the desired grain fractions would be produced, with virtually the fines can be avoided.

According to a further feature of the invention, a refraction of the glass foam plate is carried out in accordance with a sieve curve, which is deviating, especially in the smaller grain fractions strongly different, the Fuller sieve curve. In addition, however, with the method according to the invention a sieve curve is sought, which in some areas of the Fuller curve aware differs. With this sieve curve according to the method of the invention - shown in the figure - a fractionation of the individual grain groups is more economical to produce. The production of individual types of lightweight concrete is far more environmentally friendly due to the lack of fines. Furthermore, it also increases the yield.

According to a special feature of the invention, the glass foam granules are coated or flooded with a high-strength, high-viscosity binder, for example by immersion or flooding. This self-supporting soundproofing elements can be produced. Another advantage of this lightweight concrete lies in an above-average absorption behavior and the ability to carry self-supporting elements.

According to a further embodiment, the lightweight concrete is mixed with a filler material, in particular a high-strength, high-viscosity binder. Thus, high-strength, yet lightweight construction elements, such as supports made of reinforced concrete in situ concrete or as a finished part can be produced. The outstanding advantage is a very high strength with simultaneous thermal insulation and a very significant reduction in density.

In general, it can be said that the lightweight concrete according to the invention, produced by the process according to the invention, can very well fulfill the European Standard EN 13055-1 or the ÖNORM B 4200 Part 1 1.

In the following, embodiments of the practice are shown for a more detailed explanation of the invention:

There are basically two groups of applications: the manufacture of prefabricated elements, including brick production, and the production of ready-mix concrete, which also includes site concrete. Example 1: very light finished parts, highly heat-insulating and corresponding compressive strength, for example facing concrete in terrace slabs: 67-72% by volume glass foam granules of the grain group 4/8 and 8/16 with closed Komgefüge, the 28-33 VoI% Blähglaskugeln, especially with sintered surface or Pumice of grain size <4 is added as filler material.

Example 2: lightweight finished parts, thermal insulation and increased compressive strength, for example structural concrete elements:

50-55% by volume of glass foam granules of the grain groups 4/8 and 8/16 with a closed grain structure, to which 45-50% by weight of natural sand of grain size <2 is added as filler material. The grain size 2/4 is deliberately omitted.

Example 3: extremely lightweight finished parts, particularly high thermal insulation and extremely economical production, for example, monolithic wall elements for the

Building construction: 65-70% by volume of granulated glass beads of grain group 4/8 with open grain structure, containing 0.1-25% by volume of expanded glass beads of grain size <2 and 0.1% -15% by weight of expanded and / or extruded polystyrene as filler material and a foaming agent becomes. Again, the grain size 2/4 is omitted,

Example 4:

Production of bricks or bricks, in particular hollow bricks: 65-75% by volume of glass foam granules of grain group 4/8 or 8/16 (or also 8/16 or 8/12) with open grain structure containing 25-35% by volume of expanded glass spheres of grain size <2 is buried as filler material. The grain group 2/4 and optionally 4/8 is deliberately not used. Example 5: lightweight ready-mix concrete or in-situ concrete, for example for basement ceilings: 60-65% by volume of glass foam granules of grain groups 4/8 and 8/16 or 16/22 with closed grain structure, 35-40% by weight of natural sand of grain size <4 as filler material is buried.

Example 6: Extremely light ready-mix concrete or in-situ concrete, for example heat-insulating walls for industrial buildings: 60-75% by volume of glass foam granules of grain groups 4/8 and 8/16 with closed grain structure containing 25-40% by volume of expanded glass spheres or pumice of grain size <4 as filler material is buried.

Example 7: drainage-capable and heat-insulating cast-in-situ concrete, for example industrial intermediate floors:

55-75% by volume of granulated glass granules of the 16/32 or 32/50 grain group with hoveground grain, the 0.1-20% natural sand or perlite of grain size <2 and 24.9-44.9% by volume expanded and / or extruded Polystyrene (EPS / XPS) is added as filler material.

Example 8: Acid-resistant lightweight concrete, for example for biogas plants: 65-70% by volume of glass foam granules of grain groups 4/8 and 8/16 or 8/16 and 16/32 with a closed grain structure containing 30-35% by weight of expanded glass beads of particle size <4 and a sealant based on water glass with a special catalyst are buried.

Example 9: Sound-absorbing and heat-insulating leveling layer for false ceiling: 50-75% by volume of glass foam granules of grain group 16/32 or 32/50 with grain-like grain structure containing 25-50% by volume of expanded glass spheres of grain size <2 is buried It is deliberately omitted to the grain size 2/4 to 8/16 or 2/4 to 16/32

Example 1 O- super-light and high-thermal lightweight concrete for monolithic

Concrete systems in prefab or in-situ concrete method.

73% by volume of glass foam granules of group 4 - 16 with closed poπ

Compound to which 27% by volume of polystyrene of grain size 0 - 4 is added

Example 1 1 ecological and moisture-compensating lightweight concrete up to 60% by volume glass foam granules of grain group 4 - 16 with closed-pore

Korngefuge, to which up to 40% of Fasein from hemp is buried

Example 12 individually tunable, high thermal insulation lightweight concrete for wall and

Ceiling constructions, as transport or site concrete ¹

50-75% by volume of glass foam granules of the grain group 12-35 and a fullmatπx of 25-50% by volume of different density and strength produced by means of a special foaming agent

Example 13 self-supporting Schallschutzelemente- to 75 VoI% glass foam granules of the grain fraction 30/50 the

Glass foam granules are coated with a high-strength and high-viscosity special binder.

Example 14. High strength, lightweight construction elements:

40 - 75% foam glass granules of the grain group 8/16 or 30/50 (or 0/4, 4/8, 16/32) coated by means of high-strength and high-viscosity special binder and filling also with the high-strength, high-viscosity special binder As indicated above, therefore, the glass foam granules can be used as a single grain or as a multi-core. The physical properties corresponding to the lightweight concrete according to the invention, such as density, grain group, particle size distribution, grain shape, water content, grain strength and also the chemical properties, such as organic and inorganic constituents or reactivities, can be influenced by the use of the filler material.

Claims

claims:

1. lightweight concrete, which consists of glass foam granules at least one grain fraction with a binder, preferably cement, bitumen or synthetic resin, characterized in that the glass foam granules a grain fraction at least the size 2, preferably at least the size 4, and that as a fines a filler material with a Komfraktion to 4, preferably to 2, and a volume fraction of lightweight concrete of

0.1 to 50%, preferably from 0.1 to 25%.

2. Lightweight concrete according to claim 1, characterized in that a maximum of two grain fractions of the glass foam granules are used.

3. lightweight concrete according to claim 1 or 2, characterized in that the proportion of glass foam granules is a maximum of 75%.

4. Lightweight concrete according to one of claims 1 to 3, characterized in that as filler material Blähglaskugeln, preferably with a sintered

Surface, to be used.

5. Lightweight concrete according to one of claims 1 to 3, characterized in that expanded clay sand is used as the filler material.

6. lightweight concrete according to one of claims 1 to 3, characterized in that pumice is used as filler material.

7. Lightweight concrete according to one of claims 1 to 3, characterized in that the filler material used is natural sand or fly ash.

8. Lightweight concrete according to one of claims 1 to 3, characterized in that is used as filler material, preferably crushed, expanded and / or extruded polystyrene.

9. Lightweight concrete according to one of claims 1 to 3, characterized in that perlites are used as filler material.

10. Lightweight concrete according to one of claims 1 to 3, characterized in that hemp fibers are used as filler material.

1 1. Lightweight concrete according to one of claims 1 to 10, characterized in that it has a closed grain structure.

12. Lightweight concrete according to claim 11, characterized in that an air entraining agent is added.

13. Lightweight concrete according to one of claims 1 to 10, characterized in that it has an open grain structure.

14. Lightweight concrete according to claim 13, characterized in that a

Foaming agent is added.

15. Lightweight concrete according to claim 13, characterized in that a starch ether is added.

16. A process for the production of lightweight concrete according to one of claims 1 to 15, characterized in that the glass foam granules are made exclusively from a mixture of glass powder and silicon carbide, wherein in a conventional manner, the glass powder and the silicon carbide are dry mixed and then the mixture is blown in a thermal process.

17. The method according to claim 16, characterized in that the glass foam panels produced in the thermal process are treated shock-like immediately after the thermal process with a gaseous or liquid coolant.

18. The method according to claim 16 or 17, characterized in that the glass foam plates produced in the thermal process are comminuted with a mechanical device, such as a spiked roller with cutting tools.

19. The method according to any one of claims 16 to 18, characterized in that a refraction of the glass foam plate according to a sieve curve, which is deviating, especially in the smaller grain fractions strongly different, the Fuller sieve curve occurs.

20. A process for the production of lightweight concrete according to one of claims 1 to 15, characterized in that the glass foam granules with a high-strength, high-viscosity binder, for example, in the dipping or flooding process, coated or flooded.

21. A method according to claim 20, characterized in that the lightweight concrete is mixed with a filler material, in particular a high-strength, high-viscosity binder.