Classifications

• • 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
  • C04B28/02—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
  • C04B28/10—Lime cements or magnesium oxide cements
  • C04B28/12—Hydraulic lime
• • 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
• • 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
  • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
  • C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
  • C04B38/106—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam by adding preformed foams
• • 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
  • C04B2111/40—Porous or lightweight materials

Definitions

• the present invention relates to a lightened fresh concrete or mortar composition, to a process for its preparation, to products obtainable from such a cured composition, and to processes for their manufacture.
• Concretes or mortars are composed of aggregates and / or sands agglomerated by a lant.
• aggregates are grains of stone, gravel or sand.
• the mortar separates concrete from the size of the aggregates present in its composition, since a mortar is composed of sands or aggregates which are agglomerated by a lant. 3 the aggregates have a mean diameter greater than 8 mm, we speak of concrete. 3 their diameter is less than 8 mm, it will be called mortar.
• a light concrete is characterized by a lower density than a common concrete, either by its cavernous character or by the use of light aggregates such as expanded clay, expanded shale, pozzolana, pumice, polystyrene expanded, cenospheres including fly ash, expanded glass, vermiculite or perlite.
• a common concrete has a density of about 2300 kg / m 3
• a light concrete is conventionally characterized by a density of less than 1800 kg / m 3 .
• a lighter mortar includes the same types of light aggregates.
• the present invention relates to a lightened fresh concrete or mortar composition, that is to say whose density is between 500 and 1400 kg / m 3 , making it possible to obtain light cured products, the mechanical strength of which is in particular improved compared to known products comprising lightweight aggregates.
• the subject of the invention is a fresh concrete or mortar composition having a fresh density of between 500 and 1400 kg / m 3 , comprising at least:
• a mineral binder chosen from hydraulic binders, sources of calcium sulphates and lime,
• the inventors have shown that it is possible to obtain light cured products having very good mechanical performance and thermal insulation.
• the production of prefabricated products from this composition has the advantage of being easy to implement.
• the described composition has a viscosity and handling such that it can be poured into molds or formwork and then demold easily and quickly the products obtained, since they have sufficient strength to be demolded in the state fresh, without adhering to the mold.
• aqueous foam within the meaning of the present invention defines any type of foam obtained by a disordered stack of gas bubbles in an aqueous phase, in particular in a soapy liquid.
• a soap-like liquid comprises water and at least one surfactant compound.
• the aqueous foam is one of the constituents of the concrete or mortar composition, which implies that it is already pre-formed when it is mixed with the other constituents.
• the combination of an aqueous foam with light aggregates makes it possible to obtain porous concrete or mortar structures, of low density, in which the porosity is homogeneously distributed. Despite high porosity, these structures exhibit good airtightness and excellent compressive strength.
• the volumic masses of the mortar or concrete composition according to the present invention are measured fresh, i.e., once the composition comprises aqueous foam and water.
• Density measurements can also be performed on dry products after drying and curing.
• the concrete composition or light mortar according to the present invention comprises alum granules preferably selected from clays, glasses or expanded shales, having a particle density of between 400 and 1000 kg / m 3 , preferably between 400 and 600 kg / m 3 .
• composition according to the present invention may comprise, in addition to lightweight granules, up to 20% by volume of natural or artificial granules whose particle mass density is greater than 2300 kg / m 3.
• the total amount of aggregates is between 30 and 90% by volume, preferably between 50 and 70% by volume of the composition according to the present invention.
• said aqueous foam comprises the mixture of the following compounds:
• At least one cationic surfactant salt selected from one of the following compounds of the general formula: for which R is an aliphatic chain of 8 to 24 carbon atoms; F3 ⁇ 4 is a group selected from alkyls having 1 to 16 carbon atoms, hydroxyalkyls having 1 to 16 carbon atoms, a benzyl group, a group which taken together with the nitrogen of formula (I) gives a heterocycle optionally substituted with at least one fluorine atom; F3 ⁇ 4 and F3 ⁇ 4 are selected from groups consisting of an alkyl group having 1 to 6 carbon atoms, the hydroxyalkyls containing 1 to 6 carbon atoms, a hydrogen atom, a benzyl group, a group which, taken together with the nitrogen of the formula (I), gives a heterocycle optionally substituted by at least one fluorine atom; and X is a counter-ani on,
• R is an aliphatic chain of 10 to 24 carbon atoms
• X is a charge-bearing group selected from carboxylate, sulphate and phosphate groups
• Y is a counter cation selected from ammonium, sodium, potassium, calcium and magnesium
• the ratio of the weight content of the cationic surfactant salt to the weight content of the anionic surfactant salt varies from 0.05: 1 to 15: 1, preferably from 0.2: 1 to 5: 1, even 0.4: 1 at 2.5: 1.
• Said aqueous foam is formed of a mixture of at least one ionic surfactant salt.
• an "ionic surfactant salt" defi nes a surfactant taken together with the associated counter ion.
• the cat ionic surfactant salt of the aqueous foam is selected from alkyltrimethylammonium salts containing an alkyl group containing 10 to 22 carbon atoms, and is preferably selected from at least one of the following compounds: bromide (or chloride) dodecyltrimethylammonium, tetradecyltrimethylammonium bromide (or chloride), hexadecyltrimethylammonium bromide (or chloride), octadecyltrimethylammonium bromide (or chloride), cetyltrimethylammonium bromide (or chloride), cetylbenzyldi chloride hyl ammonium, cetyltriethylammonium bromide
• the anionic surfactant salt mentioned above is selected from at least one of the following compounds: ammonium stearate, potassium stearate, sodium stearate, calcium stearate and magnesium stearate.
• anionic surfactants consisting of an alkali metal salt of an organic acid carrying an aliphatic chain containing 12 to 24 carbon atoms, advantageously a sodium, potassium or ammonium salt (optionly substituted).
• the X group of the general formula (II) may be a carboxylate, sulphate or sulphonate group.
• carboxylate salts having 12 to 24 carbon atoms, selected for example from the salts of: myri state, palmitate, stearate, oleate, or the conjugate base of behenic acid; and in particular the selected anions derived from soap by hydrolysis of triglyceride (saponification).
• Mention may also be made of other carboxylates such as those derived from the treatment of tallow fatty acids, especially comprising palmitate, stearate and oleate.
• conjugated bases of fatty acids may also be used, for example soap shower gels comprising fatty acids from natural sources such as tallow, coconut oil or even palm oil.
• soap shower gels comprising fatty acids from natural sources such as tallow, coconut oil or even palm oil.
• the cationic and anionic surfactants of the aqueous foam are comprised in two distinct aqueous phases and are mixed in the contents indicated above to form the foam. The preparation of such an aqueous foam is described in WO 96/25475.
• This aqueous foam has the advantage of remaining stable, especially when mixing the various constituents of the concrete or mortar composition of the present invention.
• Cationic and anionic surfactants may be included in a single aqueous phase which is stirred vigorously to cause foaming.
• the aqueous foam can also be prepared from two-component kits marketed by Al lied Foam (referenced 425 A and 510 B). Such kits consist of a first aqueous mixture containing an anionic surfactant and a second aqueous mixture comprising a cationic surfactant and a latex.
• the volume of aqueous foam present in the composition according to the present invention represents between 5 and 50%, preferably between 5 and 30% of the total volume of said composition.
• the inorganic mineral present in the composition according to the present invention can be a hydraulic fluid chosen from Portland elements, alumina elements, sulphoaluminous elements, belicylic elements, blast furnace slags.
• pozzolanic mixing compositions possibly including fly ash, silicate fumes, limestone, calcined shale and / or natural or calcined pozzolans, singly or in combination.
• It may also be a source of calcium sulphate and may be chosen from plaster or hemihydrate, gypsum and / or anhydrite.
• the mineral lant represents 5 to 30% of the total weight of the composition.
• the composition according to the present invention is a mortar or wet concrete composition and therefore comprises water.
• the first function of the mixing water is to ensure the hydration of the mineral binder.
• the second is to give the concrete or mortar sufficient maneuverability so that it can be implemented for the desired application.
• the amount of water present in the composition depends in particular on the aggregates used. Conventionally, the ratio E3 ⁇ 4 ff / C corresponding to the ratio between the amount of effective water and the amount of inorganic binder varies between 0.2 and 0.8. Effective water is the water that is used to hydrate the mineral binder. Ble is different from the total amount of water introduced into the composition, since part of this total water is absorbed by the aggregates.
• the concrete or mortar composition according to the present invention advantageously comprises other additives or adjuvants conferring on it particular properties.
• rheological agents such as plasticizers or superplasticizers, water-retaining agents, thickening agents, biocidal protective agents, dispersing agents, pigments, accelerators and / or retarders, and also other agents which improve the setting, hardening and / or stability of the mortar or concrete after application, adjust the color, the workability, the application or the impermeability.
• the content of additives and adjuvants conventionally varies between 0.1 and 5% by weight relative to the total of inorganic binder present in the composition.
• the composition may also comprise other inert fillers, also called calcareous and / or siliceous type liquids.
• the present invention also relates to the process for preparing the lightened concrete or mortar composition described above.
• said composition is prepared on the same site, by mixing in any order in a kneader the different constituents. It is important to maintain the stability of the aqueous foam to reduce the mixing speed when said foam is introduced into the composition. By way of example, the speed of rotation is reduced by at least 30%
• the preparation of the composition can be carried out at two different sites.
• a mixture of the dry products namely aggregates, inorganic lime and inert fillers or additives, is carried out conventionally in a kneader.
• the mixture obtained is optionally stored before being transported to the site of preparation of the concrete composition or fresh mortar where the addition of the aqueous foam and water is then realisé, di rectly on the site of application of the composition.
• Building products such as masonry blocks, chimney blocks, slabs, lugs or wall construction elements, obtained after curing the lightened concrete composition or mortar described above, are also an object of the invention. the present invention. These products are preferably prefabricated. Very advantageously, these products are manufactured by a process comprising a step of molding the composition or prepared as described above, in which the said composition is poured or extruded into a mold or box, by gravity and / or by application. This is followed by a demolding step and a curing step performed outside the mold.
• the consistency of the composition according to the present invention allows immediate release of the wet product, keeping the desired shape due to good strength of the composition even before curing.
• the demolding is realisé all the more easily as the The composition according to the present invention has the advantage of not sticking to the mold.
• This method of manufacture can be advantageously implemented in a heavy-duty block compacting machine (still sometimes referred to as a block layer), or in any other automatic compacting device such as a micro-machine.
• building blocks can be obtained by pouring the concrete composition or mortar made according to the present invention into a vibrating compacting machine conventionally used for the formation of these blocks.
• the compaction time is less than 10 seconds, or even less than 5 seconds.
• the block is then removed from the compaction mold and left to harden out of the mold for 12 to 24 hours.
• these products may be manufactured by a process comprising a step of molding said composition or prepared as described above, preferably carried out in a vibrating compacting machine for blocks or in any other compaction device. automatic equivalent, wherein said composition is poured or extruded into a mold or form, by gravity and / or applying a force, a curing step performed in the mold, followed by a step of demolding the cured composition.
• an auto-calving agent it is possible to directly pour or pump said concrete or mortar composition according to the present invention onto the surface on which the dal is to be formed and then to leave it hardened. air.
• the products obtained according to these embodiments have a good mechanical strength for a low volumic mass.
• the dry products obtained have a density of less than 1400 kg / m 3 , preferably even less than 1200 kg / m 3 .
• the following examples illustrate the invention without limiting its scope.
• Chimney block elements were made from different concrete compositions and strength tests were performed on the products obtained.
• a kit supplied by Allied Foam is used (the percentages are weight contents calculated with respect to the total mass of the compositions).
• Anionic surfactant mixture belonging to the class of fatty acids 15-30%
• the foam is generated by a commercial foam generator by the company Al lied Foam.
• Component 1 is diluted with water in the following proportions: 4 parts of component 1 are mixed with 96 parts of water. About 16 parts of component 2 are introduced directly into the tank provided for this purpose.
• Compositions A to C were prepared by mixing the various constituents listed below (Table 1) in a Haarup type mixer.
• the first mixing step is carried out with an initial rotation speed: all the dry constituents are added and mixed together.
• the water is then added and additives in liquid form are introduced.
• the rotational speed is reduced by 50% with respect to the initial speed, the aqueous foam is added.
• the mixture is finished after 2 min.
• composition A Composition B
• Composition C Composition B
• compositions A and C are prepared.
• the various compositions obtained were each poured into a compaction vibrating machine, referenced Columbia Model 50, for building blocks.
• the different products A to C are respectively obtained from the compositions A and C described above.
• the products A and B obtained from the comparative compositions A and B did not make it possible to obtain chimney elements and reeds in the air.
• the resulting structures are open and let the air through.
• Product B was obtained from a composition close to composition A, but comprising a larger quantity of fine aggregates, making it possible to reduce the porosity. In order to improve the airtightness, it is found that it is necessary to densify the internal structure by limiting the presence of voids therein. It is noted that the seal is significantly improved for the product C according to the invention: the mixture of the aqueous foam and light aggregates provides a structure that is more porous and therefore lighter than conventional structures and also more airtight.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)

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• 2012
  • 2012-12-20 FR FR1262471A patent/FR3000060B1/fr not_active Expired - Fee Related
• 2013
  • 2013-12-18 WO PCT/FR2013/053162 patent/WO2014096701A1/fr active Application Filing
  • 2013-12-18 EP EP13818343.9A patent/EP2935144A1/de not_active Withdrawn

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