EP2032799A1 - Method for coating a matrix with fire, water and frost-proof barrier layer as well as layer prepared by the method - Google Patents

Method for coating a matrix with fire, water and frost-proof barrier layer as well as layer prepared by the method

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Publication number
EP2032799A1
EP2032799A1 EP07747659A EP07747659A EP2032799A1 EP 2032799 A1 EP2032799 A1 EP 2032799A1 EP 07747659 A EP07747659 A EP 07747659A EP 07747659 A EP07747659 A EP 07747659A EP 2032799 A1 EP2032799 A1 EP 2032799A1
Authority
EP
European Patent Office
Prior art keywords
layer
aplite
coating
range
weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP07747659A
Other languages
German (de)
French (fr)
Other versions
EP2032799A4 (en
Inventor
Hallvar Eide
Rune GODÖY
Arild Saasen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP2032799A1 publication Critical patent/EP2032799A1/en
Publication of EP2032799A4 publication Critical patent/EP2032799A4/en
Withdrawn legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A62—LIFE-SAVING; FIRE-FIGHTING
    • A62C—FIRE-FIGHTING
    • A62C3/00—Fire prevention, containment or extinguishing specially adapted for particular objects or places
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/16—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing anhydrite, e.g. Keene's cement
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D11/00—Lining tunnels, galleries or other underground cavities, e.g. large underground chambers; Linings therefor; Making such linings in situ, e.g. by assembling
    • E21D11/38—Waterproofing; Heat insulating; Soundproofing; Electric insulating
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00724—Uses not provided for elsewhere in C04B2111/00 in mining operations, e.g. for backfilling; in making tunnels or galleries
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/29—Frost-thaw resistance
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • Sprayable compositions have the advantage that they can e sprayed directly onto an uneven surface without need for smoothing or lathing prior to mounting of elements with a certain form and size. Transport is also simpler since it is bulk and not in the form of large elements requiring mechanical handling prior to and during mounting.
  • the disadvantage with sprayable compositions has until now been that it has not been possible to make such compositions comply with the demands to safety that exists for the most relevant fields of use.
  • the coating should have good safety in relation to fire and good properties in relation to water and frost. It is furthermore an object to be ale to make or prepare the coating by means which are inexpensive and flexible and which do not require extensive adaptations or "tailoring" for each individual application.
  • the present invention provides a method as defined by claim 1.
  • the present invention provides a coating as defined by claim 25.
  • Preferred, non-limiting embodiments of the invention are disclosed by the dependent claims.
  • micronized is understood a powdery form in which the particle size is in the range up to about 200 ⁇ m (micron).
  • a certain compound like aplite, is mainly within a defined particle size range, it is to be understood that at least 50 % by weight of the particles is in that range and preferably at least 80 %.
  • Aplite is a granite rock mainly consisting of quartz and feldspar. It occurs in different continents and is available in different qualities. Aplite is e.g. found in adjoin, Virginia, USA, Owens Valley, California, USA, Finnvolldalen in Norway, in Toscana in Italy and some places in Russia and Japan. Commercially, aplite is delivered from a.o. Maffei
  • Aplite typically contains silicon, magnesium, iron, sodium, aluminium, potassium, titanium and calcium, the main constituents being silicon and aluminium (in the form of oxides) typically being present in relative amounts in the range 60-85 % by weight and 10-25 % by weight respectively.
  • Suitable carbon fibres in the form of a separate mass or in a structured form, like woven or knitted mats, for use with the present invention can be supplied commercially from e.g. Devoid AMT, Langevaag, Norway.
  • quartz content in the aplite calculated as SiO 2 stake, within the rage 68 to 95 % by weight.
  • the first layer when hardened, constitutes a very strong concrete with a compressive strength of up to 700 bar or more. With a convenient amount of aplite this layer will not draw water from the surface beneath (the matrix) if seepage of water to this layer should occur.
  • the second layer contributes to increased strength n the form of tensile strength and ductility and contributes to form a strong bonding between the first and the third layer.
  • the second layer contributes to increased stability of the coating and the coating structure with time.
  • the third layer primarily contributes to prevent any propagation of heat in the form of open flames, since it is able to resist heat without burning or disintegrating.
  • the content of significant amounts of slag, preferably crude ore slag and calcite (CaCO 3 ) and anhydrite (CaSO 4 ) makes this layer a fire-proof barrier.
  • a typical and preferred layer thickness of the first layer is from 50 to 150 mm. This also applies for the third layer.
  • a water content in the range 40-50 % by weight of the dry substances is typically present in the settable material composition.
  • the micronized aplite mainly has a particle size less than 250 ⁇ m, preferably in the range 150-170 ⁇ m, but may also be less than 150 ⁇ m and in some cases less than 100 ⁇ m. In some embodiments it is preferred that at least 80 % o the aplite has a particle size less than 200 ⁇ m and in some embodiments it is preferred that at least 50 % of the aplite has a particle size less than 100 ⁇ m.
  • particle size it should be understood if nothing else is stated, that ii is measured by conventional measurement techniques and standard sieve sizes. Alternatively the particle size could be determined with Coulter set of apparatus for determination of particle size.
  • the micronized aplite has a quartz content of at least 68 % by weight and more preferred at east 75 % by weight of the aplite.
  • the micronized aplite can be present as the sole cement component in the composition used in the first layer, i.e. as the only bonding agent in the first layer and that the reaction that causes the layer to set is controlled by adjusting pH in the settable composition to a level lower than 7, preferably lower than 5 and readily lower than 4. Such adjustment can - be made by adding a controlled amount of a mineral acid or organic acid. Any acidizing component that not adversely effects other components in the composition can be used.
  • aplite can be used in the first layer along with at least one hydraulic cement, like a Portland cement, pozzolan cement, gypsum cement alumina cement silica cement and slag cement.
  • Such conventional hydraulic cement is typically present in the first layer in an amount in the range 15-35 % by weight of the total cement material (aplite + conventional cement material).
  • aplite + conventional cement material typically of a diameter in the range from about 5 ⁇ m to about 200 ⁇ m.
  • micro-spheres contribute a.o. to improved flowing ability of the fresh settable material composition used to form the mentioned first layer and the mentioned third layer.
  • the micro-spheres can also positively influence the strength properties and/ or other properties of the final, hardened composition constituting a layer of the coating according to the second aspect of the present invention.
  • the micro-spheres can be made in materials chosen among glass, ceramics, polymers and carbon fibres.
  • the fibres of the reinforcement layer solely comprise fibres which are non-corrosive even in an acidic environment and are preferable carbon fibres.
  • the fibres are preferably arranged in a structured form, such as, but not limited to, woven, knitted or braided form.
  • the fibres typically have a diameter in the range 1-15 ⁇ m, more preferred 3-10 ⁇ m, and most preferred 6-8 ⁇ m.
  • fibres such as carbon fibres are present as discrete fibres in the compositions forming first and/ or third layer, they preferably have a length in the range 1-100 mm and more preferred 3-25 mm.
  • the relative amount of anhydrite present in the composition forming the third layer typically is in the range 2-5 % by weight of the dry substance.
  • the relative amount of calcite in the composition forming third layer also is in the range 2-5 % by weight of the dry substance.
  • the particle sizes of anhydrite and calcite are less important than the particle size of aplite and will generally have a rather broad distribution in which most of the material, typically 70-80 % thereof, within the range 0.1 - 5 mm.
  • Micronized aplite can be present as the sole bonding agent (cement component) in the composition used to form the third layer and the reaction causing the layer to set is controlled by adjusting pH of the settable material composition to a value lower than 7, preferably lower than 6, and more preferred lower than 5.
  • micro-spheres having a typical diameter in the range from about 5 ⁇ m to about 200 ⁇ m can be included as well as discrete carbon fires as mentioned in relation to the composition of the first layer.
  • the matrix or the surface onto which the first layer is applied is typically an internal mountain wall that has been exposed by a technique chosen among drilling and blasting and optionally subsequent washing or cleaning, most typically wall surfaces and/ or ceiling surfaces in a tunnel, typically a tunnel for transportation, such as for roads or railway.
  • the invention comprises a complete coating comprising at least three layers formed by any combination of the features described in connection with the method constituting the first aspect of the invention.
  • the coating which is particularly suited as a fire, frost and water-proof coating in tunnels, thus comprises a first layer of a set material composition comprising micronized aplite, another layer in the for of a reinforcement layer and a third layer of a set material composition comprising aplite, anhydrite, slag and calcite.
  • the coating according to this aspect of the invention thus comprises the respective stakes of the individual components which above have been defined with reference to the method constituting the first aspect of the invention.
  • Aplite from all known occurrences can be used though it is preferred that the aplite has a silicate (quartz) content of at least 68 % by weight and more preferred at least 75 %.
  • At least one of the layers chosen among first and third layer can include aplite granulate as an aggregate.
  • materials chosen from materials like sand, gravel, anhydrite, glass, and foamed glass can be used as aggregate in the first and third layers.
  • the coating according to the present invention will during setting typically shrink less than 3 %, preferably less than 1.5 % and most preferred less than 0.7 %.
  • the method and the coating according to the present invention can be well suited for a number of applications of which the most obvious today is for coating of wall tunnels, particularly road tunnels with coatings that fulfil the strict demands for safety in the fields water, frost and not least fire.
  • composition according to the invention satisfies such demands since especially the third layer with its content of slag, aplite, calcite (CaCO 3 ) and anhydrite (CaSO 4 ) form a strongly fire resistant barrier while the other layers contribute to provide strength to the structure.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Mining & Mineral Resources (AREA)
  • Civil Engineering (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Geology (AREA)
  • Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Business, Economics & Management (AREA)
  • Emergency Management (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Lining And Supports For Tunnels (AREA)

Abstract

Method for coating a matrix with a fire, water and frost-proof barrier as well as the coating thus manufactured. The matrix, which can be a wall in a tunnel, is sprayed-on a first layer of a settable material composition comprising micronized aplite. Then at least one layer of fibre reinforcement is applied on top of the first layer whereafter another layer of sprayable settable material composition is sprayed-on. This third layer comprises aplite, anhydrite, slag and calcite. Both the first and the third layer may also contain conventional hydraulic cements. The applied layers are allowed to set to a hard material.

Description

Method for coating a matrix with fire, water and frost proof barrier layer as well as layer prepared by the method
Background
In a number of connections it is desirable to coat a surface or matrix with a coating that is water, frost, and fire-proof and in some connections rigid law regulations apply to use of such coating.
With regard to tunnels, especially road tunnels, there have been a number of severe fire accidents in recent years which has led to a strong focus on choice of materials used in such environments. With regard to applications techniques for such kind of coatings, it can vary from use of prefabricated elements to spraying-on of settable compositions of mortar and optional additions. An advantage with the prefabricated elements is that the composition of the elements is simpler to control when it is not required that any component be sprayable. In addition it is not necessary to use water in any component and it is simper to find compositions that satisfies requirements related to fire, water and frost safety.
Sprayable compositions have the advantage that they can e sprayed directly onto an uneven surface without need for smoothing or lathing prior to mounting of elements with a certain form and size. Transport is also simpler since it is bulk and not in the form of large elements requiring mechanical handling prior to and during mounting. The disadvantage with sprayable compositions has until now been that it has not been possible to make such compositions comply with the demands to safety that exists for the most relevant fields of use.
Objects
It is thus an object of the present invention to provide a method for making or preparing coatings on a matrix, such as a mountain wall, like a tunnel wall. The coating should have good safety in relation to fire and good properties in relation to water and frost. It is furthermore an object to be ale to make or prepare the coating by means which are inexpensive and flexible and which do not require extensive adaptations or "tailoring" for each individual application. The present invention
According to a first aspect the present invention provides a method as defined by claim 1.
According to a second aspect the present invention provides a coating as defined by claim 25. Preferred, non-limiting embodiments of the invention are disclosed by the dependent claims.
By "micronized" is understood a powdery form in which the particle size is in the range up to about 200 μm (micron). When it is stated that a certain compound, like aplite, is mainly within a defined particle size range, it is to be understood that at least 50 % by weight of the particles is in that range and preferably at least 80 %.
Aplite is a granite rock mainly consisting of quartz and feldspar. It occurs in different continents and is available in different qualities. Aplite is e.g. found in Montpellier, Virginia, USA, Owens Valley, California, USA, Finnvolldalen in Norway, in Toscana in Italy and some places in Russia and Japan. Commercially, aplite is delivered from a.o. Maffei
Natural Resources, Italy and from US Silica Company, West Virginia, USA: Aplite typically contains silicon, magnesium, iron, sodium, aluminium, potassium, titanium and calcium, the main constituents being silicon and aluminium (in the form of oxides) typically being present in relative amounts in the range 60-85 % by weight and 10-25 % by weight respectively.
Suitable carbon fibres in the form of a separate mass or in a structured form, like woven or knitted mats, for use with the present invention can be supplied commercially from e.g. Devoid AMT, Langevaag, Norway.
In connection with the invention it is desirable with a quartz content in the aplite, calculated as SiO2 stake, within the rage 68 to 95 % by weight.
By the method and the coating according to the present invention there is provided a three layer structure that each in different ways contributes to the overall properties in the formed coating. The first layer, when hardened, constitutes a very strong concrete with a compressive strength of up to 700 bar or more. With a convenient amount of aplite this layer will not draw water from the surface beneath (the matrix) if seepage of water to this layer should occur.
The second layer, the reinforcement layer, contributes to increased strength n the form of tensile strength and ductility and contributes to form a strong bonding between the first and the third layer. In addition the second layer contributes to increased stability of the coating and the coating structure with time.
The third layer primarily contributes to prevent any propagation of heat in the form of open flames, since it is able to resist heat without burning or disintegrating. The content of significant amounts of slag, preferably crude ore slag and calcite (CaCO3) and anhydrite (CaSO4) makes this layer a fire-proof barrier. Preferred embodiments
Below a number of preferred, on-limiting embodiments of the invention is described.
For application of the first and third layer per se conventional spraying equipment intended for cement containing settable material compositions may be used. A typical and preferred layer thickness of the first layer is from 50 to 150 mm. This also applies for the third layer.
When applying the first layer, a water content in the range 40-50 % by weight of the dry substances is typically present in the settable material composition.
The micronized aplite mainly has a particle size less than 250 μm, preferably in the range 150-170 μm, but may also be less than 150 μm and in some cases less than 100 μm. In some embodiments it is preferred that at least 80 % o the aplite has a particle size less than 200 μm and in some embodiments it is preferred that at least 50 % of the aplite has a particle size less than 100 μm. When t is referred to particle size it should be understood if nothing else is stated, that ii is measured by conventional measurement techniques and standard sieve sizes. Alternatively the particle size could be determined with Coulter set of apparatus for determination of particle size.
The micronized aplite has a quartz content of at least 68 % by weight and more preferred at east 75 % by weight of the aplite.
The micronized aplite can be present as the sole cement component in the composition used in the first layer, i.e. as the only bonding agent in the first layer and that the reaction that causes the layer to set is controlled by adjusting pH in the settable composition to a level lower than 7, preferably lower than 5 and readily lower than 4. Such adjustment can - be made by adding a controlled amount of a mineral acid or organic acid. Any acidizing component that not adversely effects other components in the composition can be used. In other preferred embodiments, aplite can be used in the first layer along with at least one hydraulic cement, like a Portland cement, pozzolan cement, gypsum cement alumina cement silica cement and slag cement. Such conventional hydraulic cement is typically present in the first layer in an amount in the range 15-35 % by weight of the total cement material (aplite + conventional cement material). In the composition sprayed-on to form the first layer discrete carbon fibres and/ or microspheres can be present, the latter typically of a diameter in the range from about 5 μm to about 200 μm. Such micro-spheres contribute a.o. to improved flowing ability of the fresh settable material composition used to form the mentioned first layer and the mentioned third layer. By a convenient choice of micro-spheres, the micro-spheres can also positively influence the strength properties and/ or other properties of the final, hardened composition constituting a layer of the coating according to the second aspect of the present invention. The micro-spheres can be made in materials chosen among glass, ceramics, polymers and carbon fibres.
The fibres of the reinforcement layer solely comprise fibres which are non-corrosive even in an acidic environment and are preferable carbon fibres. The fibres are preferably arranged in a structured form, such as, but not limited to, woven, knitted or braided form.
The fibres typically have a diameter in the range 1-15 μm, more preferred 3-10 μm, and most preferred 6-8 μm. When fibres such as carbon fibres are present as discrete fibres in the compositions forming first and/ or third layer, they preferably have a length in the range 1-100 mm and more preferred 3-25 mm.
The relative amount of anhydrite present in the composition forming the third layer typically is in the range 2-5 % by weight of the dry substance. The relative amount of calcite in the composition forming third layer also is in the range 2-5 % by weight of the dry substance.
The particle sizes of anhydrite and calcite are less important than the particle size of aplite and will generally have a rather broad distribution in which most of the material, typically 70-80 % thereof, within the range 0.1 - 5 mm.
Micronized aplite can be present as the sole bonding agent (cement component) in the composition used to form the third layer and the reaction causing the layer to set is controlled by adjusting pH of the settable material composition to a value lower than 7, preferably lower than 6, and more preferred lower than 5.
Also in the composition for the third layer micro-spheres having a typical diameter in the range from about 5 μm to about 200 μm can be included as well as discrete carbon fires as mentioned in relation to the composition of the first layer.
The matrix or the surface onto which the first layer is applied is typically an internal mountain wall that has been exposed by a technique chosen among drilling and blasting and optionally subsequent washing or cleaning, most typically wall surfaces and/ or ceiling surfaces in a tunnel, typically a tunnel for transportation, such as for roads or railway.
According to a further aspect the invention comprises a complete coating comprising at least three layers formed by any combination of the features described in connection with the method constituting the first aspect of the invention.
The coating, which is particularly suited as a fire, frost and water-proof coating in tunnels, thus comprises a first layer of a set material composition comprising micronized aplite, another layer in the for of a reinforcement layer and a third layer of a set material composition comprising aplite, anhydrite, slag and calcite. The coating according to this aspect of the invention thus comprises the respective stakes of the individual components which above have been defined with reference to the method constituting the first aspect of the invention. Aplite from all known occurrences can be used though it is preferred that the aplite has a silicate (quartz) content of at least 68 % by weight and more preferred at least 75 %.
It is by the way possible to use quartz also from other sources than aplite in the first and third layers.
At least one of the layers chosen among first and third layer can include aplite granulate as an aggregate. Incidentally also materials chosen from materials like sand, gravel, anhydrite, glass, and foamed glass can be used as aggregate in the first and third layers.
The coating according to the present invention will during setting typically shrink less than 3 %, preferably less than 1.5 % and most preferred less than 0.7 %.
The method and the coating according to the present invention can be well suited for a number of applications of which the most obvious today is for coating of wall tunnels, particularly road tunnels with coatings that fulfil the strict demands for safety in the fields water, frost and not least fire.
The composition according to the invention satisfies such demands since especially the third layer with its content of slag, aplite, calcite (CaCO3) and anhydrite (CaSO4) form a strongly fire resistant barrier while the other layers contribute to provide strength to the structure.

Claims

Claims
1. Method of covering a matrix with a fire, water and frost-proof barrier, characterized in spraying the matrix a first layer of a settable material composition comprising micronized aplite, thereafter covering the formed layer with at least one layer of fibre reinforcement and thereafter spray-coating a layer of settable material composition comprising aplite, anhydrite, slag, and calcite.
2. Method as claimed in claim 1 , characterized in that per se conventional spraying equipment is used for spray coating of the first and third layer.
3. Method as claimed in claim 1 , characterized in that the first layer is applied with a thickness between 50 and 150 mm.
4. Method as claimed in claim 1 , characterized in that the first layer when applied has a water content in the range 40-50 % by weight of the of the dry substance.
5. Method as claimed in claim 1 , characterized in that the micronized aplite mainly is of a particle size in the range 150-170 μm.
6. Method as claimed in claim 1 , characterized in that the micronized aplite has a quartz content of at least 68 % by weight and more preferred at least 75 % by weight of the aplite.
7. Method as claimed in claim 1 , characterized in that the micronized aplite is present as the sole bonding agent in the first layer ad that the reaction that causes the layer to set is controlled by adjusting pH of the settable material composition to a value lower than 7, preferably lower than 6, and more preferred lower than 5.
8. Method as claimed in claim 1 , characterized in that the first layer also comprises a hydraulic cement such as a Portland cements, pozzolan cement, gypsum cement, alumina cement, silica cement or slag cement.
9. Method as claimed in claim 1 , characterized in that the hydraulic cement is present in the first layer in an amount in the range 15-35 % by weight of the total weight of cement material (aplite + other cement material).
10. Method as claimed in claim 1 , characterized in that discrete carbon fibres are present in the settable material composition of the first layer.
11. Method as claimed in claim 1, characterized in that micro-spheres with a diameter in the range 5 - 200 μm are present in the settable material composition of the first layer.
12. Method as claimed in claim 1 , characterized in that the reinforcement layer comprises fibres which are non-corrosive even in an acid environment.
13. Method as claimed in claim 12, characterized in that the fibres are carbon fibres.
14. Method as claimed in claim 12 or 13, characterized in that the fibres are arranged in a structured form such as but not limited to, woven, knitted, or braided form.
15. Method as claimed in claim 14, characterized in that the carbon fibres have a diameter in the range 1-15 μm, more preferred 3-10 μm and most preferred 6-8 μm.
16. Method as claimed in claim 1 , characterized in that the third layer is applied with a thickness in the range 50 - 150 mm.
17. Method as claimed in claim 1 , characterized in that anhydrite is present in the third layer in an amount in the range 2-5 % by weight of the dry substance.
18. Method as claimed in claim 1 or 17, characterized in that the particle size of the anhydrite mainly is in the range 0.1 to 5 mm.
19. Method as claimed in claim 1, characterized in that calcite is present in an amount in the range 2-5 % by weight of the dry substance.
20. Method as claimed in claim 1 or 19, characterized in that the particle size of calcite mainly is in the range 01 to 5 mm.
21. Method as claimed in claim 1 , characterized in that the micronized aplite is present as the sole bonding agent in the third layer ad that the reaction that causes the layer to set is controlled y adjusting pH of the settable material composition to a value lower than 7.
22. Method as claimed in claim 1 , characterized in that micro-spheres with a diameter in the range from about 5 μm to about 200 μm are included in the settable material composition of the third layer.
23. Method as claimed in claim 1 , characterized in that the matrix that is covered by the first layer is an internal mountain wall which has been exposed by a technique chosen among drilling and blasting.
24. Method as claimed in claim 23, characterized in that the internal mountain wall comprises wall and ceiling of a tunnel.
25. Coating for internal surfaces in tunnels, characterized in comprising a first layer of a settable material composition comprising micronized aplite, a second layer which is a reinforcement layer, and a third layer formed from a settable ass comprising aplite, anhydrite, slag and calcite. ^
26. Coating for internal surfaces in runnels, characterized in being formed by means of a method according to any one of the claims 1-24 and subsequent curing or setting.
27. Coating as claimed in claim 25 or 26, characterized in that the first layer comprises at least 65 % by weight of micronized aplite.
28. Coating as claimed in claim 25 or 26, characterized in that the third layer comprises at least 75 % by weight of micronized aplite and up to 25 % by weight of an hydraulic cement, calculated of the dry substance of cement components.
29. Coating as claimed in claim 21 or 22, characterized in that at least 80 % of the aplite has a particle size les than 200 μm.
30. Coating as claimed in claim 21 or 22, characterized in that at least 50 % of the aplite has a particle size less than about 100 micron.
31. Coating as claimed in claim 21 or 22, characterized in that the aplite has a silicate (quartz) content o at least 68 % by weight and ore preferred at least 75 %.
32. Coating as claimed in claim 21 or 22, characterized in that at least one of the layers chosen among first and third layer has a content of quartz also from other sources than aplite.
33. Coating as claimed in claim 21 or 22, characterized in that aplite granules as an aggregate has been added to at least one layer chosen among first and third layer.
34. Coating as claimed in claim 21 or 22, characterized in that at least one of the following materials are used as a aggregate: sand, gravel, anhydrite, glass, foamed glass.
35. Coating as claimed in claim 21 or 22, characterized in that the coating during setting shrinks less than 3 %, preferably less than 1.5 % and most preferred less than 0.7 %.
EP07747659A 2006-06-12 2007-06-11 Method for coating a matrix with fire, water and frost-proof barrier layer as well as layer prepared by the method Withdrawn EP2032799A4 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO20062731A NO325801B1 (en) 2006-06-12 2006-06-12 Method of dressing a matrix with a fire-, water- and frost-proof barrier, as well as so formed clothing.
PCT/NO2007/000202 WO2008004874A1 (en) 2006-06-12 2007-06-11 Method for coating a matrix with fire, water and frost-proof barrier layer as well as layer prepared by the method

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EP2032799A1 true EP2032799A1 (en) 2009-03-11
EP2032799A4 EP2032799A4 (en) 2011-09-28

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CN101787895B (en) * 2010-03-01 2011-12-07 河南理工大学 Double-layer folding heat-insulated barrel for use in coal mine roadway
AU2014200344B2 (en) * 2013-02-05 2017-03-02 Promat Research and Technology Centre NV Fire Protection Mortar

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WO2002028799A1 (en) * 2000-10-05 2002-04-11 Promat International N.V. Fire-proof material
EP1382795A1 (en) * 2002-07-16 2004-01-21 Vinci Construction Grands Projets Tunnel lining comprising a layer of refractory mortar
JP2004224622A (en) * 2003-01-22 2004-08-12 Taiheiyo Cement Corp Refractory coating cement mortar composition for injection
JP2005120349A (en) * 2003-09-16 2005-05-12 Raito Kogyo Co Ltd Material for earth and sand structure, surface protecting construction method for inclined face, lining face, and tunnel lining face using the same, and slope protecting construction method
JP2005187275A (en) * 2003-12-26 2005-07-14 Nippon Koatsu Concrete Kk Fire-resisting and heat-resisting concrete and its manufacturing method
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EP1028095A1 (en) * 1997-07-16 2000-08-16 Toho Rayon Co., Ltd. Reinforcing material, method of production thereof, reinforcing/repairing method using the reinforcing material, reinforcing/repairing structure, and structural element
WO2002028799A1 (en) * 2000-10-05 2002-04-11 Promat International N.V. Fire-proof material
EP1382795A1 (en) * 2002-07-16 2004-01-21 Vinci Construction Grands Projets Tunnel lining comprising a layer of refractory mortar
JP2004224622A (en) * 2003-01-22 2004-08-12 Taiheiyo Cement Corp Refractory coating cement mortar composition for injection
JP2005120349A (en) * 2003-09-16 2005-05-12 Raito Kogyo Co Ltd Material for earth and sand structure, surface protecting construction method for inclined face, lining face, and tunnel lining face using the same, and slope protecting construction method
JP2005187275A (en) * 2003-12-26 2005-07-14 Nippon Koatsu Concrete Kk Fire-resisting and heat-resisting concrete and its manufacturing method
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NO325801B1 (en) 2008-07-21
NO20062731L (en) 2007-12-13
WO2008004874A1 (en) 2008-01-10
EP2032799A4 (en) 2011-09-28
RU2009100133A (en) 2010-07-20

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