EP3148953A1 - Method for manufacturing a composition of lightweight concrete or mortar - Google Patents

Method for manufacturing a composition of lightweight concrete or mortar

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Publication number
EP3148953A1
EP3148953A1 EP15732789.1A EP15732789A EP3148953A1 EP 3148953 A1 EP3148953 A1 EP 3148953A1 EP 15732789 A EP15732789 A EP 15732789A EP 3148953 A1 EP3148953 A1 EP 3148953A1
Authority
EP
European Patent Office
Prior art keywords
composition
mixture
concrete
foaming agent
mortar
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Withdrawn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
EP15732789.1A
Other languages
German (de)
French (fr)
Inventor
Elodie Taboulot
Geir Ove Norden
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.)
Saint Gobain Weber SA
Original Assignee
Saint Gobain Weber SA
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 Saint Gobain Weber SA filed Critical Saint Gobain Weber SA
Publication of EP3148953A1 publication Critical patent/EP3148953A1/en
Withdrawn legal-status Critical Current

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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
    • 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
    • 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
    • B28B23/0081—Embedding aggregates to obtain particular properties
    • B28B23/0087—Lightweight aggregates for making lightweight articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/003—Methods for mixing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/38—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions wherein the mixing is effected both by the action of a fluid and by directly-acting driven mechanical means, e.g. stirring means ; Producing cellular concrete
    • B28C5/381—Producing cellular concrete
    • 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

Definitions

  • the present invention relates to a method of manufacturing a lightweight concrete or mortar composition, the composition obtained by this process has products that can be obtained from such a composition once cured.
  • 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, crushed and milled slags, vermiculite or pearlite.
  • a common concrete has a density of about 2300 kg / m 3
  • a lightweight concrete is conventionally characterized by a density of less than 2000 kg / m 3 .
  • a lightweight mortar includes the same types of lightweight aggregates. It is in this context of research of new materials al legés and performance mechanically and thermally that s' is written the present invention.
  • Application WO 01/70647 discloses a process for producing a hydraulic binder foam comprising a step of preparing an aqueous foam before mixing it with the hydraulic binder.
  • the foam is thus pre-formed by air injection to produce a stable foam, before being mixed with the other constituents.
  • the hydraulic binder foam is then put into the desired shape in order to obtain, after setting, a finished product.
  • the present invention relates to a process for manufacturing a lightened concrete or mortar composition, that is to say whose density is between 200 and 1400 kg / m 3 , said composition making it possible to obtain cured products light, whose mechanical strength is improved in particular compared to known products comprising lightweight aggregates.
  • the manufacturing method of the lightened concrete or mortar composition is characterized in that it comprises the mixture of constituents comprising at least lightweight aggregates of density of particles of between 50 and 1000 kg / m 3 , at least one mineral binder. selected from hydraulic binders, sources of calcium sulphates and lime, at least one foaming agent and water, optionally one or more additives, the foaming agent being a polyvinyl alcohol, its foaming being done in situ during its mixture with water and with at least one of the components selected by the granules and / or the inorganic binder.
  • the advantage of this process makes it possible in particular to directly use polyvinyl alcohol as an air-entraining agent, which makes it possible to obtain a moderate foaming of the composition while controlling and increasing the viscosity of the mixture.
  • the fact of being able to carry out the in-situ foaming directly during the preparation of the lightened concrete or mortar composition makes it possible to simplify the process and to eliminate the pre-generation stage of the foam, requiring most of the time to use also during this step of the foam stabilizers.
  • polyvinyl alcohol has the advantage, in addition to its foaming power, of modifying the viscosity of the mixture so that the air bubbles generated during in situ foaming are trapped in the fresh composition and are not released during mixing, the transport, compact ion or hardening of the composition.
  • foaming power it is possible to trap air bubbles, but most often foaming is much more difficult to control because too fast and a strong rise of air bubbles is made to the surface, reducing the lightening power.
  • Polyvinyl alcohol also has the advantage of being in compliance with the Environment, Health and Safety standards.
  • the method according to the invention makes it possible to manufacture a fresh concrete or mortar composition which, once hardened, makes it possible to significantly reduce the weight of the materials obtained by reducing their density, while maintaining the mechanical strengths.
  • the thermal properties are also improved.
  • the formation of the foam from the foaming agent present in the mixture is in-situ during the mixing of the various constituents and therefore during the preparation of the concrete composition or mortar. No gas injection, such as compressed air, is required to obtain foaming.
  • the method according to the present invention does not include a step of pre-generation of the foam and does not implement a foam generator The foam is generated during the mixing of the various constituents of the concrete composition or mortar.
  • the polyvinyl alcohol used in the process according to the invention has a degree of hydrolysis of between 65 and 99 mol%, preferably between 70 and 99 mol%.
  • the preferred polyvinyl alcohols are those having a viscosity of at least 3cP, when measured in solution at a concentration of 4% in water at 20 ° C.
  • the process according to the invention may comprise the mixture of another foaming agent, for example of the cationic, anionic, zwitterionic and / or nonionic surfactant type.
  • the only foaming agent used in the process according to the present invention consists of one or more polyvinyl alcohols. Foaming remains sufficient, controlled and stable over time using only polyvinyl acid.
  • the polyvinyl alcohol may be in powder form or in liquid form, in the form of an aqueous solution.
  • the content of polyvinyl alcohol is less than 10% by weight, preferably between 0.01% and 8% by weight relative to the total mixture of the various constituents, preferably between 0.01% and 5% by weight and even more preferably between 0.05% and 2% by weight.
  • the addition of the foaming agent is carried out directly in the mixer in which the mortar or concrete composition is prepared, the foaming agent being introduced either in the form of a dry powder or in the form of an aqueous solution.
  • the various constituents of the mixture namely the lightened granules, the inorganic binder, the foaming agent and the water can be introduced in any order into the mixer.
  • the method according to the present invention comprises mixing the various constituents in the following way:
  • the lighter granules, the water and the foaming agent are mixed together in the mixer, then the inorganic binder is added to the mixture thus formed.
  • the mixing time required for the appearance of the foam during the step of adding the foaming agent is between 10 and 180 seconds.
  • the mixing time after the addition of the inorganic binder is between 1 and 5 minutes, preferably between 1 and 3 minutes.
  • the water used in the manufacturing process can be advantageously heated before being introduced into the mixture, so as to obtain a mortar or concrete composition at a temperature of 20 to 25 ° C.
  • This temperature advantageously makes it possible to promote the foaming of the polyvinyl alcohol and consequently to reduce the amounts of foaming agent necessary to obtain the desired lightening.
  • the lightened granules used in the process according to the present invention are chosen from expanded clays, expanded shales, pozzolans, pumice stones, expanded polystyrenes, cenospheres. including fly ash, expanded glass, crushed and ground slags, vermiculite or perlite, crushed cork aggregates and ground tire waste aggregates having a particle density of between 50 and 1000 kg / m 3 preferably between 200 and 600 kg / m 3
  • the content of aggregates in the mixture is between 10 and 95% by weight, preferably between 30 and 95% by weight of the total mixture of the various constituents.
  • the expanded clay content having a particle diameter greater than 2 mm preferably represents more than 50% by weight of the expanded clays.
  • the process according to the invention advantageously makes it possible to obtain lightened construction products having the desired properties in terms of mechanical strength, despite the large amount of coarse light aggregates (that is to say the particle diameter of which is greater than 2 mm).
  • the mixture includes, in addition to lightened aggregates, up to 20% by volume of natural or artificial aggregates with a density of particles greater than 2300 kg / m 3 .
  • the inorganic binder used in the process according to the present invention may be a hydraulic binder chosen from Portland cements, aluminous cements, sulphoaluminous cements, belicylic cements, blast furnace slags, pozzolanic mixture cements possibly comprising ashes. flying, silica fumes, limestone, calcined shale and / or natural or calcined pozzolans, alone or as a mixture. It can also be a source of calcium sulphate and be selected from plaster or hemihydrate, gypsum and / or anhydrite. It can also be lime.
  • the inorganic binder may be an acid-base binder such as a phospho-magnesium cement. These different types of binders can be used alone or in mixture. The inorganic binder represents between 5 and 40% by weight of the total mixture of different constituents.
  • the manufacturing method according to the present invention makes it possible to obtain a wet or fresh concrete or mortar composition, since one of the constituents of the mixture is water.
  • the first function of water is to ensure the hydration of the mineral binder.
  • the second function is to give the concrete or mortar sufficient maneuverability so that it can be for the desired application.
  • the amount of water used in the process depends in particular on the aggregates used in the mixture. In a conventional manner, the ratio El C corresponding to the ratio between the amount of water and the amount of inorganic binder varies between 0.2 and 1.0. Part of the water, called effective water is the water that is used to hydrate the mineral binder. It is different from the total amount of water introduced into the process since some of this total water is absorbed by the aggregates.
  • additives or additives conferring particular properties on the concrete or mortar composition may be added during the mixing of the various constituents.
  • examples include rheological agents such as plasticizers or superplasticizers, water-retaining agents, thickening agents, biocidal protective agents, dispersing agents, water-repellent agents, pigments, accelerators and / or retarders, and also other agents to improve the setting, hardening and / or stability of the mortar or concrete after application, to adjust the color, the workability, the implementation or the impermeability.
  • the total content of additives and adjuvants conventionally varies between 0.001% and 5% by weight relative to the total composition of the constituents used in the process.
  • inert fillers also called fi lers, limestone and / or siliceous type.
  • the present invention also relates to a mortar or concrete composition obtained according to the process described above.
  • Building products such as masonry blocks, chimney blocks, slabs, lintels, panels or wall construction elements, obtained after curing the lightened concrete composition or mortar described above, are also an object of this invention. invention. These products are preferentially prefabricated.
  • these products are manufactured by a process comprising a step of molding the concrete or mortar composition obtained according to the process of the present invention in which said composition is poured or extruded into a mold or formwork, by gravity and / or applying a force, i mmediatement followed by a step of demolding, and a curing step performed outside the mold.
  • the consistency of the composition obtained according to the process of 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 made all the easier as the resulting composition has the advantage of not sticking to the mold.
  • This method of manufacture can be advantageously implemented in a vibrating block compacting machine (still sometimes called a block-laying machine), or in any other automatic compaction device if such a machine.
  • building blocks can be obtained by pouring the concrete or mortar composition obtained from the process according to the present invention into a compacting 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 can be manufactured by a process comprising a step of molding said composition prepared as described above, preferably made in an automatic compacting device, in which said composition is poured or extruded into a mold or formwork, by gravity and / or applying a force, a curing step performed in the mold, followed by a step of demolding the cured composition.
  • the curing time is about 24 hours.
  • the products obtained according to these embodiments have good mechanical strength for a low density. They have good airtightness and good thermal conductivity properties. They are also characterized by low water absorption when they are placed, once cured, in the moist atmosphere.
  • the dry products obtained have a density in the dry state of between 200 and 1400 kg / m 3 , or even preferably less than 900 kg / m 3 .
  • the examples below illustrate the invention without limiting its scope.
  • the amounts of the various constituents are given by weight.
  • the bulk densities of the light aggregates used were measured and are given below to within ⁇ 10% for each of the values:
  • Granulat type Leca® round 2-6 mm 350 kg / m 3 .
  • the airtightness measurements are made according to an internal procedure used for chimney blocks, as described below. Two plates each having soft corners covering the corners are placed on each side of a sample. One of the plates has an air inlet pipe, and the other plate is flat. Air at a pressure of 50 Pa is introduced to one side of the sample. Once the air flow through the sample is stabilized, the amount of outgoing air is measured. The test is considered satisfactory when the quantity of outgoing air measured is less than or equal to 1 m 3 / h.
  • Example 1 Process for the Production of Stacked Blocks with a Polyvinyl Alcohol A Foaming Agent
  • An aqueous solution of foaming agent containing 15% of polyvinyl alcohol is prepared as follows: 15 g of polyvinyl alcohol A sold under the trade name Sel vol TM having a degree of hydrolysis of 87% and a viscosity of 5 cP measured in solution at a concentration of 4% in water at 20 ° C are mixed with 85 g of water for a period of 24 hours. After preparation, this solution is stored at a temperature of 20 ° C. Light aggregates are introduced into the concrete mixer. The cement is added, then the mixing water. Once all the water is introduced, the 15% aqueous salt solution is added. The concrete composition is mixed for a period of 2 to 4 minutes, until a stable and homogeneous foam is obtained.
  • Table 1 gives the quantities of the various constituents introduced to form 1 m 3 of concrete.
  • Example 2 Process for producing chimney blocks with a polyvinyl alcohol B as a foaming agent
  • a different foaming agent is used, namely a polyvinyl alcohol B, sold under the trade name Sel vol TM, which has a viscosity of 23 cP measured in solution at a concentration of 4% in water at 20 ° C. and a degree of hydrolysis of 87% in the form of a powder.
  • Light aggregates are introduced into the concrete mixer.
  • the cement and the polyvinyl alcohol powder B and then the mixing water are added.
  • the content of foaming agent in this composition represents 0.3% by weight of the total mass of the various constituents.
  • the polyvinyl alcohol B is introduced into the mixer in powder form, along with the light aggregates and water. These constituents are mixed for about 120 seconds until a foam is obtained. The cement is then introduced into the mixer. The whole is mixed for 90 to 120 seconds.
  • the content of foaming agent in the compositions 3 and 4 represents 0.3% by weight of the total mass of the various constituents. Ble is 0.33% by weight in the composition 5.
  • Example 4 (Comparative): A method of manufacturing conventional chimney blocks.
  • Two concrete compositions not comprising foaming agent were prepared by mixing the various constituents listed in Table 7 below with a sand whose bulk density is 1200 kg / m 3 .
  • composition C1 Composition C2
  • Example 5 Process for manufacturing light weight diapers 100 mm * 190mm * 500mm
  • the content of foaming agent in the compositions 6 and 7 represents respectively 0.3% by weight and 0.4% by weight of the total mass of the various constituents.
  • the physical characteristics measured on the hardened blocks outside the mold obtained from the compositions described in Table 7 are given below (Table 10):
  • Example 6 A method of manufacturing bl ocs di mensions 100mm * 190mm * 500mm The method of introducing the various constituents in the concrete mixer is identical to cel ui described in Example 3.
  • composition 8a was prepared and is described in Table 11 below.
  • the content of foaming agent in the composition 8 represents 0.5% by weight of the total mass of the various constituents.

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

Abstract

The invention relates to a method for manufacturing a composition of lightweight concrete or mortar having a dry density of 200 to 1400 kg/m3 into which are mixed components comprising at least light aggregates with a particle density of 50 to 1000 kg/m3, at least one mineral binder selected among the hydraulic binders, the sources of calcium sulphates and lime, at least one foaming agent and water, and optionally one or more additives, said foaming agent being a polyvinyl alcohol and the foaming thereof occurring in place during the mixing thereof with water and at least one of the components selected from among the aggregates and/or the mineral binder.

Description

PROCEDE DE FABRICATION D' UNE COMPOSTION DE BÉTON OU MORTIER  PROCESS FOR THE PRODUCTION OF A CONCRETE OR MORTAR COMPOSITION
ALLÉGÉ  LIGHTWEIGHT
La présente invention concerne un procédé de fabrication d' une composition de béton ou mortier al légé, la composition obtenue selon ce procédé ai nsi que des produits susceptibles d' être obtenus à parti r d' une tel le composition une fois durcie. The present invention relates to a method of manufacturing a lightweight concrete or mortar composition, the composition obtained by this process has products that can be obtained from such a composition once cured.
De nombreux travaux dans le domaine de la construction portent actuel lement sur la recherche de matériaux et produits allégés, qui , étant moins denses, exercent moi ns de contraintes sur le support sur lequel ils sont déposés et permettent ainsi d' obtenir des structures pl us légères. Il reste toutefois i mportant que ces matériaux gardent de bonnes propriétés tant mécaniques (tenue mécanique, résistance aux chocs, résistance aux divers stress mécaniques) que t hermiques.  Many works in the field of construction are currently focused on the search for lighter materials and products, which, being less dense, exert me constraints on the support on which they are deposited and thus make it possible to obtain structures light. It remains important, however, that these materials retain good mechanical properties (mechanical strength, impact resistance, resistance to various mechanical stresses) and hermetic properties.
Les bétons ou mortiers sont composés de granulats et/ ou sables agglomérés par un l iant . Dans les bétons courants, les granulats sont des grains de pierre, graviers ou sable. Le mortier se disti ngue du béton par la taille des granulats présents dans sa composition, puisqu' un mortier est composé de sables ou granulats f ins agglomérés par un l iant . 3 les granulats ont un diamètre moyen supérieur à 8 mm, on parlera de béton. 3 leur diamètre est inférieur à 8 mm, on parlera de mortier. Un béton léger est caractérisé par une densité pl us faible qu' un béton courant, soit par son caractère caverneux, soit par uti lisation de granulats légers tels que les argi les expansées, les schistes expansés, des pouzzolanes, des pierres ponces, des polystyrènes expansés, des cénosphères notamment de cendres volantes, du verre expansé, des laitiers concassés et broyés, de la vermicul ite ou de la perl ite. Alors qu' un béton courant a une masse volumique d' environ 2300 kg/ m3, un béton léger se caractérise de façon classique par une masse vol umique i nférieure à 2000 kg/ m3. De la même manière, un mortier al légé comprend les mêmes types de granulats légers. C' est dans ce cadre de recherche de nouveaux matériaux al légés et performants mécaniquement et thermiquement que s' i nscrit la présente invention. On connaît de la demande WO 01/70647 un procédé de production d'une mousse de liant hydraulique comprenant une étape de préparation d'une mousse aqueuse avant son mélange avec le liant hydraulique. La mousse est ainsi pré-formée par injection d'air pour produire une mousse stable, avant d'être mélangée aux autres constituants. La mousse de liant hydraulique est ensuite mise sous la forme souhaitée afin d'obtenir, après prise, un produit fini. Concretes or mortars are composed of aggregates and / or sands agglomerated by a lant. In common concretes, 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, crushed and milled slags, vermiculite or pearlite. While a common concrete has a density of about 2300 kg / m 3 , a lightweight concrete is conventionally characterized by a density of less than 2000 kg / m 3 . In the same way, a lightweight mortar includes the same types of lightweight aggregates. It is in this context of research of new materials al legés and performance mechanically and thermally that s' is written the present invention. Application WO 01/70647 discloses a process for producing a hydraulic binder foam comprising a step of preparing an aqueous foam before mixing it with the hydraulic binder. The foam is thus pre-formed by air injection to produce a stable foam, before being mixed with the other constituents. The hydraulic binder foam is then put into the desired shape in order to obtain, after setting, a finished product.
La présente invention porte sur un procédé de fabrication d'une composition de béton ou mortier allégé, c'est-à-dire dont la masse volumique est comprise entre 200 et 1400 kg/ m3, ladite composition permettant d'obtenir des produits durcis légers, dont la résistance mécanique est notamment améliorée par rapport à des produits connus comprenant des granulats allégés. The present invention relates to a process for manufacturing a lightened concrete or mortar composition, that is to say whose density is between 200 and 1400 kg / m 3 , said composition making it possible to obtain cured products light, whose mechanical strength is improved in particular compared to known products comprising lightweight aggregates.
Le procédé de fabrication de la composition de béton ou mortier allégé est caractérisé en ce qu'il comprend le mélange de constituants comprenant au moins des granulats allégés de masse volumique de particules comprise entre 50 et 1000 kg/ m3, au moins un liant minéral choisi parmi les liants hydrauliques, les sources de sulfates de calcium et la chaux, au moins un agent moussant et de l'eau, éventuellement un ou plusieurs additifs, l'agent moussant étant un alcool polyvinylique, son moussage se faisant in-situ lorsde son mélange avec l'eau et avec au moins un des constituant s choisi s par mi les granulats et/ ou le liant minéral. The manufacturing method of the lightened concrete or mortar composition is characterized in that it comprises the mixture of constituents comprising at least lightweight aggregates of density of particles of between 50 and 1000 kg / m 3 , at least one mineral binder. selected from hydraulic binders, sources of calcium sulphates and lime, at least one foaming agent and water, optionally one or more additives, the foaming agent being a polyvinyl alcohol, its foaming being done in situ during its mixture with water and with at least one of the components selected by the granules and / or the inorganic binder.
L'avantage de ce procédé permet notamment d'utiliser directement l'alcool polyvinylique comme entraîneur d'air, ce qui permet d'obtenir un moussage modéré de la composition, tout en contrôlant et en augmentant la viscosité du mélange. Le fait de pouvoir réaliser directement le moussage in- situ lors de la préparation de la composition de béton ou mortier allégé permet de simplifier le procédé et de supprimer l'étape de pré-génération de la mousse, nécessitant la plupart du temps d' utiliser également lorsde cette étape des agents stabilisateurs de mousse. Par rapport aux tensioactifs usuels qui pourraient être utilisés pour la fabrication de composition de béton ou mortier allégé, comme par exemple des tensioactifs anioniques, cationiques, zwitterioniques et/ ou non ioniques ou leur mélange, l'alcool polyvinylique présente l'avantage, en plus de son pouvoir moussant, de modifier la viscosité du mélange de telle sorte que les bulles d'air générées lors du moussage in- situ sont piégées dans la composition fraîche et ne sont pas libérées pendant le mélangeage, le transport, la compact ion ou le durcissement de la composition. Avec des tensioactifs classiques, il est possible de piéger des bulles d'air, mais le plus souvent le moussage est nettement plus difficilement contrôlable car trop rapide et une forte remontée des bulles d'air se fait àlasurface, réduisant le pouvoir allégeant. L'alcool polyvinylique présente également l'avantage d'être conforme aux normes Environnement, Hygiène et Sécurité. The advantage of this process makes it possible in particular to directly use polyvinyl alcohol as an air-entraining agent, which makes it possible to obtain a moderate foaming of the composition while controlling and increasing the viscosity of the mixture. The fact of being able to carry out the in-situ foaming directly during the preparation of the lightened concrete or mortar composition makes it possible to simplify the process and to eliminate the pre-generation stage of the foam, requiring most of the time to use also during this step of the foam stabilizers. With respect to the usual surfactants that could be used for the manufacture of lightened concrete composition or mortar, such as anionic, cationic, zwitterionic and / or nonionic surfactants or their mixture, polyvinyl alcohol has the advantage, in addition to its foaming power, of modifying the viscosity of the mixture so that the air bubbles generated during in situ foaming are trapped in the fresh composition and are not released during mixing, the transport, compact ion or hardening of the composition. With conventional surfactants, it is possible to trap air bubbles, but most often foaming is much more difficult to control because too fast and a strong rise of air bubbles is made to the surface, reducing the lightening power. Polyvinyl alcohol also has the advantage of being in compliance with the Environment, Health and Safety standards.
Le procédé selon l'invention permet de fabriquer une composition fraîche de béton ou mortier, qui, une fois durcie, permet de réduire de façon importante le poids des matériaux obtenus en réduisant leur densité, tout en maintenant les résistances mécaniques. Les propriétés thermiques sont également améliorées.  The method according to the invention makes it possible to manufacture a fresh concrete or mortar composition which, once hardened, makes it possible to significantly reduce the weight of the materials obtained by reducing their density, while maintaining the mechanical strengths. The thermal properties are also improved.
La formation de la mousse à partir de l'agent moussant présent dans le mélange se fait in-situ pendant le malaxage des différents constituants et donc pendant la préparation de la composition de béton ou mortier. Aucune injection de gaz, comme par exemple de l'air comprimé, n'est nécessaire pour obtenir le moussage. Le procédé selon la présente invention ne comprend pas d'étape de pré-génération de la mousse et ne met pas en œuvre un générateur de mousse La mousse est générée pendant le mélange des différents constituants de la composition de béton ou mortier.  The formation of the foam from the foaming agent present in the mixture is in-situ during the mixing of the various constituents and therefore during the preparation of the concrete composition or mortar. No gas injection, such as compressed air, is required to obtain foaming. The method according to the present invention does not include a step of pre-generation of the foam and does not implement a foam generator The foam is generated during the mixing of the various constituents of the concrete composition or mortar.
L'alcool polyvinylique utilisé dans le procédé selon l'invention a un degré d' hydrolyse compris entre 65 et 99 %molaire, de préférence entre 70 et 99 %molaire. Les alcools polyvinyliques préférés sont ceux ayant une viscosité d'au moins 3 cP, lorsqu'elle est mesurée en solution à une concentration de 4%dans l'eau à 20°C. En choisissant ainsi l'alcool polyvinylique, on s'assure qu'il est suffisamment soluble dans l'eau utilisée dans la composition d'une part et d'autre part que le moussage soit suffisant.  The polyvinyl alcohol used in the process according to the invention has a degree of hydrolysis of between 65 and 99 mol%, preferably between 70 and 99 mol%. The preferred polyvinyl alcohols are those having a viscosity of at least 3cP, when measured in solution at a concentration of 4% in water at 20 ° C. By choosing polyvinyl alcohol in this way, it is ensured that it is sufficiently soluble in the water used in the composition on the one hand and on the other hand that the foaming is sufficient.
En plus de l'agent moussant à base d'alcool polyvinylique, le procédé selon l'invention peut comprendre le mélange d'un autre agent moussant, par exemple de type tensioactif cationique, anionique, zwitterionique et/ ou non ionique. De façon préférée, le seul agent moussant utilisé dans le procédé selon la présente invention est constitué d'un ou plusieurs alcools polyvinyliques. Le moussage reste suffisant, contrôlé et stable dans le temps en utilisant uniquement un acide polyvinylique. In addition to the foaming agent based on polyvinyl alcohol, the process according to the invention may comprise the mixture of another foaming agent, for example of the cationic, anionic, zwitterionic and / or nonionic surfactant type. Preferably, the only foaming agent used in the process according to the present invention consists of one or more polyvinyl alcohols. Foaming remains sufficient, controlled and stable over time using only polyvinyl acid.
L'alcool polyvinylique peut se présenter sous forme pulvérulente ou sous forme liquide, sous forme d'une solution aqueuse.  The polyvinyl alcohol may be in powder form or in liquid form, in the form of an aqueous solution.
La teneur en alcool polyvinylique est inférieure à 10% en poids, de préférence comprise entre 0,01%et 8%en poids par rapport au mélange total des différents constituants, de préférence entre 0,01% et 5% en poids et encore plus préférentiellement entre 0,05%et 2%en poids.  The content of polyvinyl alcohol is less than 10% by weight, preferably between 0.01% and 8% by weight relative to the total mixture of the various constituents, preferably between 0.01% and 5% by weight and even more preferably between 0.05% and 2% by weight.
L'ajout de l'agent moussant est réalisé directement dans le mélangeur dans lequel la composition de mortier ou béton est préparée, l'agent moussant étant introduit soit sous forme de poudre sèche, soit sous forme d'une solution aqueuse. Les différents constituants du mélange, à savoir les granulat s allégés, le liant minéral, l'agent moussant et l'eau peuvent être introduits dans un ordre quelconque dans le mélangeur.  The addition of the foaming agent is carried out directly in the mixer in which the mortar or concrete composition is prepared, the foaming agent being introduced either in the form of a dry powder or in the form of an aqueous solution. The various constituents of the mixture, namely the lightened granules, the inorganic binder, the foaming agent and the water can be introduced in any order into the mixer.
Selon un mode de réalisation préféré, le procédé selon la présente invention comprend le mélange des différents constituants de la façon suivante :  According to a preferred embodiment, the method according to the present invention comprises mixing the various constituents in the following way:
les granulat s allégés, l'eau et l'agent moussant sont mélangés ensemble dans le mélangeur, puis le liant minéral est ajouté au mélange ainsi formé. La durée de mélange nécessaire à l'apparition de la mousse lors de l'étape d'ajout de l'agent moussant est comprise entre 10 et 180 secondes. La durée de malaxage après l'ajout du liant minéral est comprise entre 1 et 5 minutes, de préférence entre 1 et 3 minutes. the lighter granules, the water and the foaming agent are mixed together in the mixer, then the inorganic binder is added to the mixture thus formed. The mixing time required for the appearance of the foam during the step of adding the foaming agent is between 10 and 180 seconds. The mixing time after the addition of the inorganic binder is between 1 and 5 minutes, preferably between 1 and 3 minutes.
L'eau utilisée dans le procédé de fabrication peut être avantageusement chauffée avant d'être introduite dans le mélange, de façon à obtenir une composition de mortier ou béton à une température de 20 à 25°C. Cette température permet avantageusement de favoriser le moussage de l'alcool polyvinylique et par conséquent de diminuer les quantités d'agent moussant nécessaire pour obtenir l'allégement souhaité.  The water used in the manufacturing process can be advantageously heated before being introduced into the mixture, so as to obtain a mortar or concrete composition at a temperature of 20 to 25 ° C. This temperature advantageously makes it possible to promote the foaming of the polyvinyl alcohol and consequently to reduce the amounts of foaming agent necessary to obtain the desired lightening.
Les granulat s allégés utilisés dans le procédé selon la présente invention sont choisis parmi les argiles expansées, les schistes expansés, les pouzzolanes, les pierres ponces, les polystyrènes expansés, les cénosphères notamment de cendres volantes, le verre expansé, les laitiers concassés et broyés, la vermiculite ou la perlite, les granulats de liège broyé et les granulats de déchets de pneus broyés, possédant une masse volumique des particules comprise entre 50 et 1000 kg/ m3, de préférence entre 200 et 600 kg/ m3 La teneur en granulats dans le mélange est comprise entre 10 et 95%en poids, de préférence entre 30 et 95%en poids du mélange total des différents constituants. Lorsque les granulats allégés sont des argiles expansées, le teneur en argile expansé ayant un diamètre de particules supérieur à 2 mm représente de préférence plus de 50%en poids des argiles expansées. Le procédé selon l'invention permet avantageusement d'obtenir des produits de construction allégés possédant les propriétés recherchées en terme de résistance mécanique, malgré la quantité importante de granulats légers grossiers (c'est-à-dire dont le diamètre des particules est supérieur à 2 mm). The lightened granules used in the process according to the present invention are chosen from expanded clays, expanded shales, pozzolans, pumice stones, expanded polystyrenes, cenospheres. including fly ash, expanded glass, crushed and ground slags, vermiculite or perlite, crushed cork aggregates and ground tire waste aggregates having a particle density of between 50 and 1000 kg / m 3 preferably between 200 and 600 kg / m 3 The content of aggregates in the mixture is between 10 and 95% by weight, preferably between 30 and 95% by weight of the total mixture of the various constituents. When the lightened aggregates are expanded clays, the expanded clay content having a particle diameter greater than 2 mm preferably represents more than 50% by weight of the expanded clays. The process according to the invention advantageously makes it possible to obtain lightened construction products having the desired properties in terms of mechanical strength, despite the large amount of coarse light aggregates (that is to say the particle diameter of which is greater than 2 mm).
II est possible que le mélange comprenne, en plus des granulats allégés, jusqu'à 20% en volume de granulats naturels ou artificiels dont la masse volumique de particules est supérieure à 2300 kg/ m3. It is possible that the mixture includes, in addition to lightened aggregates, up to 20% by volume of natural or artificial aggregates with a density of particles greater than 2300 kg / m 3 .
Le liant minéral utilisé dans le procédé selon la présente invention peut être un liant hydraulique choisi parmi les ciments Portland, les ciments alumineux, les ciments sulfoalumineux, les ciments béli tiques, les laitiers de haut fourneau, les ciments de mélange pouzzolaniques comprenant éventuellement des cendres volantes, des fumées de silice, du calcaire, du schiste calciné et/ ou des pouzzolanes naturelles ou calcinées, seuls ou en mélange. Il peut être également une source de sulfate de calcium et être choisi parmi le plâtre ou hémihydrate, le gypse et/ ou l'anhydrite. Il peut également être de la chaux. Le liant minéral peut être un liant acido-basique tel qu'un ciment phospho-magnésien. Ces différents types de liants peuvent être utilisés seuls ou en mélange. Le liant minéral représente entre 5 et 40% en poids du mélange total des différent s constituant s.  The inorganic binder used in the process according to the present invention may be a hydraulic binder chosen from Portland cements, aluminous cements, sulphoaluminous cements, belicylic cements, blast furnace slags, pozzolanic mixture cements possibly comprising ashes. flying, silica fumes, limestone, calcined shale and / or natural or calcined pozzolans, alone or as a mixture. It can also be a source of calcium sulphate and be selected from plaster or hemihydrate, gypsum and / or anhydrite. It can also be lime. The inorganic binder may be an acid-base binder such as a phospho-magnesium cement. These different types of binders can be used alone or in mixture. The inorganic binder represents between 5 and 40% by weight of the total mixture of different constituents.
Le procédé de fabrication selon la présentation permet d'obtenir une composition de béton ou mortier humide ou fraîche, puisqu'un des constituants du mélange est de l'eau. La première fonction de l'eau est d'assurer l'hydratation du liant minéral. La seconde fonction est de conférer au béton ou mortier la maniabilité suffisante pour qu'il puisse être mis en œuvre pour l'application souhaitée. La quantité d'eau utilisée dans le procédé dépend notamment des granulats utilisés dans le mélange. De façon classique, le rapport El C correspondant au rapport entre la quantité d'eau et la quantité de liant minéral varie entre 0,2 et 1,0. Une partie de l'eau, appelée eau efficace est l'eau qui sert à l'hydratation du liant minéral. Ble est différente de la quantité d'eau totale introduite dans le procédé, puisqu' une partie de cette eau totale est absorbée par les granulats. The manufacturing method according to the present invention makes it possible to obtain a wet or fresh concrete or mortar composition, since one of the constituents of the mixture is water. The first function of water is to ensure the hydration of the mineral binder. The second function is to give the concrete or mortar sufficient maneuverability so that it can be for the desired application. The amount of water used in the process depends in particular on the aggregates used in the mixture. In a conventional manner, the ratio El C corresponding to the ratio between the amount of water and the amount of inorganic binder varies between 0.2 and 1.0. Part of the water, called effective water is the water that is used to hydrate the mineral binder. It is different from the total amount of water introduced into the process since some of this total water is absorbed by the aggregates.
D'autres additifs ou adjuvants conférant des propriétés particulières à la composition de béton ou mortier peuvent être ajoutés lors du mélange des différents constituants. On citera par exemple les agents rhéologiques tels que les plastifiants ou les superplastifiants, les agents rétenteurs d'eau, les agents épaississants, les agents de protection biocides, des agents dispersants, des agents hydrofuges de masse, des pigments, des accélérateurs et/ ou retardateurs, et également d'autres agents permettant d'améliorer la prise, le durcissement et/ ou la stabilité du mortier ou béton après application, d'ajuster la couleur, la maniabilité, la mise en œuvre ou l'imperméabilité. La teneur totale en additifs et adjuvants varie classiquement entre 0,001%et 5%en poids par rapport à la composition totale des constituants mis en œuvre dans le procédé.  Other additives or additives conferring particular properties on the concrete or mortar composition may be added during the mixing of the various constituents. Examples include rheological agents such as plasticizers or superplasticizers, water-retaining agents, thickening agents, biocidal protective agents, dispersing agents, water-repellent agents, pigments, accelerators and / or retarders, and also other agents to improve the setting, hardening and / or stability of the mortar or concrete after application, to adjust the color, the workability, the implementation or the impermeability. The total content of additives and adjuvants conventionally varies between 0.001% and 5% by weight relative to the total composition of the constituents used in the process.
II est également possible d'ajouter au mélange d'autres charges inertes, encore appelées fi Mers, de type calcaires et/ ou siliceuses.  It is also possible to add to the mixture other inert fillers, also called fi lers, limestone and / or siliceous type.
La présente invention porte également sur une composition de mortier ou béton obtenu selon le procédé décrit ci -dessus. The present invention also relates to a mortar or concrete composition obtained according to the process described above.
Les produits de constructions tels que des blocs de maçonnerie, des blocs de cheminée, des dalles, deslinteaux, des panneaux ou desélémentsde construction murale, obtenus après durcissement de la composition de béton ou mortier allégé décrite ci-dessus sont également un objet de la présente invention. Ces produits sont préférentiellement préfabriqués. Building products such as masonry blocks, chimney blocks, slabs, lintels, panels or wall construction elements, obtained after curing the lightened concrete composition or mortar described above, are also an object of this invention. invention. These products are preferentially prefabricated.
De façon très avantageuse, ces produits sont fabriqués par un procédé comprenant une étape de moulage de la composition de béton ou mortier obtenue selon le procédé de la présente invention dans laquelle ladite composition est versée ou extrudée dans un moule ou coffrage, par gravité et/ ou en appl iquant une force, i mmédiatement suivie par une étape de démoulage, et une étape de durcissement réalisée en dehors du moule. La consistance de la composition obtenue selon le procédé de la présente invention permet d' effectuer un démoulage i mmédiat du produit humide, en gardant la forme souhaitée en raison d' une bonne résistance de la composition même avant durcissement . Le démoulage est réal isé d' autant pl us aisément que la composition obtenue présente l ' avantage de ne pas col ler au moule. Very advantageously, these products are manufactured by a process comprising a step of molding the concrete or mortar composition obtained according to the process of the present invention in which said composition is poured or extruded into a mold or formwork, by gravity and / or applying a force, i mmediatement followed by a step of demolding, and a curing step performed outside the mold. The consistency of the composition obtained according to the process of 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 made all the easier as the resulting composition has the advantage of not sticking to the mold.
Ce procédé de fabrication peut être mis en œuvre de façon avantageuse dans une machine vibrante de compactage de blocs (encore parfois appelée pondeuse à blocs), ou dans tout autre dispositif de compactage automatique si milaire. Ainsi , par exemple, des blocs de construction peuvent être obtenus en versant la composition de béton ou mortier obtenue à partir du procédé selon la présente i nvention dans une machine vi brante de compactage classiquement util isée pour la formation de ces blocs. La durée de compactage est inférieure à 10 secondes, voire même inférieure à 5 secondes. Le bloc est ensuite extrait du moule de compaction et est laissé pour durcissement hors du moule pour une durée comprise entre 12 et 24 heures.  This method of manufacture can be advantageously implemented in a vibrating block compacting machine (still sometimes called a block-laying machine), or in any other automatic compaction device if such a machine. Thus, for example, building blocks can be obtained by pouring the concrete or mortar composition obtained from the process according to the present invention into a compacting 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.
Selon un autre mode de réalisation, ces produits peuvent être fabriqués par un procédé comprenant une étape de moulage de ladite composition préparée telle que décrit précédemment , réal isée de préférence dans un dispositif de compactage automatique, dans laquel le ladite composition est versée ou extrudée dans un moule ou coffrage, par gravité et/ ou en appl iquant une force, une étape de durcissement réalisée dans le moule, suivie par une étape de démoulage de la composition durcie. Habituellement , la durée de durcissement est d' environ 24 heures.  According to another embodiment, these products can be manufactured by a process comprising a step of molding said composition prepared as described above, preferably made in an automatic compacting device, in which said composition is poured or extruded into a mold or formwork, by gravity and / or applying a force, a curing step performed in the mold, followed by a step of demolding the cured composition. Usually, the curing time is about 24 hours.
Les produits obtenus selon ces modes de réal isation présentent une bonne résistance mécanique pour une masse vol umique fai ble. Ils ont une bonne étanchéité à l ' ai r et possèdent de bonnes propriétés de conductivité thermique. Ils sont également caractérisés par une fai ble absorption d' eau lorsqu' ils sont placés, une fois durcis, en at mosphère humide. Les produits secs obtenus ont une masse volumique à l'état sec comprise entre 200 et 1400 kg/ m3, voire de préférence inférieure à 900 kg/ m3. Les exemples ci -après illustrent l'invention sans en limiter la portée. The products obtained according to these embodiments have good mechanical strength for a low density. They have good airtightness and good thermal conductivity properties. They are also characterized by low water absorption when they are placed, once cured, in the moist atmosphere. The dry products obtained have a density in the dry state of between 200 and 1400 kg / m 3 , or even preferably less than 900 kg / m 3 . The examples below illustrate the invention without limiting its scope.
Dans les différents exemples ci-dessous les quantités des différents constituants sont données en poids. Les densités en vrac des granulats légers utilisés ont été mesurées et sont données ci -dessous à ± 10% près pour chacune des valeurs : In the various examples below, the amounts of the various constituents are given by weight. The bulk densities of the light aggregates used were measured and are given below to within ± 10% for each of the values:
Granulat léger type Leca®, concassé, 0-1,5 mm : 330 kg/ m3 Lightweight Leca® type granulate, crushed, 0-1.5 mm: 330 kg / m 3
Granulat léger type Leca®, concassé 1,5-4mm : 310 kg/ m3 Leca® lightweight granulate, crushed 1.5-4mm: 310 kg / m 3
Granulat léger type Leca®, concassé 2,5-5mm : 310 kg/ m3 Lightweight Leca® granulate, crushed 2,5-5mm: 310 kg / m 3
Granulat léger type Leca® rond 4-10 mm : 285 kg/ m3 Light aggregate type Leca® round 4-10 mm: 285 kg / m 3
Granulat léger type Leca® rond 2-6 mm : 350 kg/ m3. Granulat type Leca® round 2-6 mm: 350 kg / m 3 .
Les mesures de résistance à la compression ont été effectuées selon la norme EN 772-1. The compressive strength measurements were made according to EN 772-1.
Les mesures d'étanchéité à l'air sont effectuées selon une procédure interne utilisée pour des blocs de cheminée, comme décrite ci-après. Deux plaques possédant chacune des encoignures souples recouvrant les angles sont placées de chaque côté d'un échantillon. Une des plaques possède un tuyau d'arrivée d'air, et l'autre plaque est plane. De l'air à une pression de 50 Pa est introduit d'un côté de l'échantillon. Une fois que le flux d'air traversant l'échantillon est stabilisé, la quantité d'air sortant est mesurée. Le test est considéré comme satisfaisant lorsque la quantité d'air sortant mesurée est inférieure ou égale à 1 m3/ h. The airtightness measurements are made according to an internal procedure used for chimney blocks, as described below. Two plates each having soft corners covering the corners are placed on each side of a sample. One of the plates has an air inlet pipe, and the other plate is flat. Air at a pressure of 50 Pa is introduced to one side of the sample. Once the air flow through the sample is stabilized, the amount of outgoing air is measured. The test is considered satisfactory when the quantity of outgoing air measured is less than or equal to 1 m 3 / h.
Exemple 1 : Procédé de fabrication de blocs cheminées avec un alcool polyvinylique Acomme agent moussant Example 1 Process for the Production of Stacked Blocks with a Polyvinyl Alcohol A Foaming Agent
Une solution aqueuse d'agent moussant à 15% d'alcool polyvinylique est préparée de la façon suivante : 15 g d'alcool polyvinylique A commercialisé sous la marque Sel vol™ ayant un degré d'hydrolyse de 87%et une viscosité de 5 cP mesurée en solution à une concentration de 4%dans l'eau à 20°Csont mélangés avec 85 g d'eau, pendant une durée de 24 heures. Apres préparation, cette solution est stockée à une température de 20°C. Les granulats légers sont introduits dans le mélangeur à béton. Le ciment est ajouté, puis l'eau de gâchage. Une fois que la totalité de l'eau est introduite, la solution aqueuse de Sel vol™à 15%est ajoutée. La composition de béton est mélangée pendant une durée de 2 à 4 minutes, jusqu'à obtention d'une mousse stable et homogène. An aqueous solution of foaming agent containing 15% of polyvinyl alcohol is prepared as follows: 15 g of polyvinyl alcohol A sold under the trade name Sel vol ™ having a degree of hydrolysis of 87% and a viscosity of 5 cP measured in solution at a concentration of 4% in water at 20 ° C are mixed with 85 g of water for a period of 24 hours. After preparation, this solution is stored at a temperature of 20 ° C. Light aggregates are introduced into the concrete mixer. The cement is added, then the mixing water. Once all the water is introduced, the 15% aqueous salt solution is added. The concrete composition is mixed for a period of 2 to 4 minutes, until a stable and homogeneous foam is obtained.
Le tableau 1 ci-dessous donne les quantités des différents constituants introduits pour former 1 m3 de béton. Table 1 below gives the quantities of the various constituents introduced to form 1 m 3 of concrete.
Tableau 1  Table 1
Note : la quantité de Selvol introduite par rapport à la totalité des Note: the amount of Selvol introduced in relation to all
constituants du mélange représente 0,5 %en poids étant donné que l'alcool polyvinylique est introduit sous la forme d'une solution aqueuse à 15% Les caractéristiques physiques mesurées sur les blocs de cheminées durcis à l'extérieur du moule obtenus à partir de la composition 1 décrite dans le tableau 1 sont données ci -dessous (tableau 2) : components of the mixture represents 0.5% by weight since the polyvinyl alcohol is introduced in the form of a 15% aqueous solution The physical characteristics measured on the hardened outside mold block blocks obtained from the composition 1 described in Table 1 are given below (Table 2):
Tableau 2  Table 2
Le procédé selon l'invention permet d'obtenir des blocs de cheminées ayant une structure poreuse donc plus légère que les structures classiques, en maintenant une bonne étanchéité à l'air. .Exemple 2 : Procédé de fabrication de blocs de cheminées avec un alcool polyvinylique B comme agent moussant  The process according to the invention makes it possible to obtain blocks of chimneys having a porous structure, which is therefore lighter than conventional structures, while maintaining a good airtightness. Example 2: Process for producing chimney blocks with a polyvinyl alcohol B as a foaming agent
Dans cet exemple, on utilise un agent moussant différent, à savoir un alcool polyvinylique B, commercialisé sous la marque Sel vol™ qui possède une viscosité de 23 cP mesurée en solution à une concentration de 4%dans l'eau à 20°C et un degré d' hydrolyse de 87% sous forme d' une poudre. In this example, a different foaming agent is used, namely a polyvinyl alcohol B, sold under the trade name Sel vol ™, which has a viscosity of 23 cP measured in solution at a concentration of 4% in water at 20 ° C. and a degree of hydrolysis of 87% in the form of a powder.
Les granulats légers sont introduits dans le mélangeur à béton. Le ciment et la poudre d'alcool polyvinylique B, puis l'eau de gâchage sont ajoutés. Light aggregates are introduced into the concrete mixer. The cement and the polyvinyl alcohol powder B and then the mixing water are added.
Le tableau 3 ci-dessous donne les quantités des différents constituants introduits pour former 1 m3 de béton. Composition 2 Table 3 below gives the quantities of the various constituents introduced to form 1 m 3 of concrete. Composition 2
Leca® broyé 0-1 , 5 mm 120  Ground Leca® 0-1, 5 mm 120
Kg/ m3 de béton Kg / m 3 of concrete
Leca® rond 4-10 mm 91  Leca® round 4-10 mm 91
Kg/ m3 de béton Kg / m 3 of concrete
Leca® rond 2-6 mm 191  Round Leca® 2-6 mm 191
Kg/ m3 de béton Kg / m 3 of concrete
Q ment EN 197-1 -CEM I 42.5 P 218  In accordance with EN 197-1 -MEM I 42.5 P 218
Norcem Industri (Kg/ m3 de béton) Norcem Industri (Kg / m 3 concrete)
Alcool polyvinyl ique B 2, 2  Polyvinyl alcohol B 2, 2
Kg/ m3 de béton Kg / m 3 of concrete
Eau aj outée 1 12  Water added 1 12
Kg/ m3 de béton Kg / m 3 of concrete
Total (kg/ ma de béton) 734 Total (kg / m to concrete) 734
Tableau 3  Table 3
La teneur en agent moussant dans cette composition représente 0, 3%en poids de la masse totale des différents constituants. The content of foaming agent in this composition represents 0.3% by weight of the total mass of the various constituents.
Les caractéristiques physiques mesurées sur les blocs de chemi nées durcis à l ' extérieur du moule obtenus à partir de la composition 2 décrite dans le tableau 3 sont données ci -dessous (tableau 4) : The physical characteristics measured on the hardened outer casing blocks obtained from composition 2 described in Table 3 are given below (Table 4):
Tableau 4 .Exemple 3 : Procédé de fabrication de blocs cheminées avec de l'alcool polvvinylique B comme agent moussant. Table 4 EXAMPLE 3 Process for the Production of Stacked Blocks with Polyvinyl Alcohol B as Foaming Agent
Le même type de produit que celui décrit dans les exemples 1 et 2 est préparé en modifiant l'ordre d'introduction des constituants dans le mélangeur à béton. The same type of product as that described in Examples 1 and 2 is prepared by changing the order of introduction of the constituents into the concrete mixer.
Selon cet exemple, l'alcool polyvinylique B est introduit dans le mélangeur sous forme de poudre, en même temps que les granulats légers et l'eau. Ces constituants sont mélangés pendant environ 120 secondes, jusqu'à obtention d'une mousse. Le ciment est ensuite introduit dans le mélangeur. L'ensemble est mélangé pendant 90 à 120 secondes.  According to this example, the polyvinyl alcohol B is introduced into the mixer in powder form, along with the light aggregates and water. These constituents are mixed for about 120 seconds until a foam is obtained. The cement is then introduced into the mixer. The whole is mixed for 90 to 120 seconds.
Trois différentes compositions ont ainsi été préparées et sont décrites dans le tableau 5 ci -dessous. Three different compositions have thus been prepared and are described in Table 5 below.
Tableau 5  Table 5
La teneur en agent moussant dans les compositions 3 et 4 représente 0,3%en poids de la masse totale des différents constituants. Ble est de 0,33% en poids dans la composition 5. The content of foaming agent in the compositions 3 and 4 represents 0.3% by weight of the total mass of the various constituents. Ble is 0.33% by weight in the composition 5.
Les caractéristiques physiques mesurées sur les blocs de cheminées durcis à l'extérieur du moule obtenus à partir des compositions décrites dans le tableau 5 sont données ci -dessous (tableau 6). Produit Masse volumique Résistance à la Banchéité à l'air à l'état sec compression m3 / h (50Pa) (kg/ m3) mesurée à 28 The physical characteristics measured on the hardened outside stack blocks obtained from the compositions described in Table 5 are given below (Table 6). Product Density Compressive air resistance in dry state compression m 3 / h (50Pa) (kg / m 3 ) measured at 28
jours (MPa)  days (MPa)
Blocs de cheminées 790 11 0,8  Fireplace blocks 790 11 0,8
composition 3 composition 3
Blocs de cheminées 770 10,4 0,9  Fireplace blocks 770 10.4 0.9
composition 4 composition 4
Blocs de cheminées 736 9,6 0,8  Fireplace blocks 736 9,6 0,8
composition 5 composition 5
Tableau 6 Ces essais montrent qu'il est possible de faire varier le liant minéral et de diminuer la quantité de liant minéral et donc de diminuer la densité des produits obtenus et leur coût, tout en maintenant leurs performances physiques et notamment leur étanchéité à l'air. .Exemple 4 (comparatif): Procédé de fabrication de blocs de cheminée convent i onnel s al I éqés.  Table 6 These tests show that it is possible to vary the inorganic binder and reduce the amount of inorganic binder and thus reduce the density of the products obtained and their cost, while maintaining their physical performance and in particular their watertightness. air. Example 4 (Comparative): A method of manufacturing conventional chimney blocks.
Deux compositions de béton ne comprenant pas d'agent moussant ont été préparées en mélangeant les différents constituants listés dans le tableau 7 ci -dessous avec un sable dont la densité en vrac est de 1200 kg/ m3. Two concrete compositions not comprising foaming agent were prepared by mixing the various constituents listed in Table 7 below with a sand whose bulk density is 1200 kg / m 3 .
Composition C1 Composition C2 Composition C1 Composition C2
Leca® broyé 0-1 , 5 mm 0 86  Leca® ground 0-1, 5 mm 0 86
Kg/ m3 de béton Kg / m 3 of concrete
Leca® rond 4-10 mm 286 164  Leca® round 4-10 mm 286 164
Kg/ m3 de béton Kg / m 3 of concrete
Leca® rond 1 , 5-5 mm 0 94  Leca® round 1, 5-5 mm 0 94
Kg/ m3 de béton Kg / m 3 of concrete
Ci ment -CEM I 42.5 R 100 200  Cement I - I 42.5 R 100 200
Kg/ m3 de béton Kg / m 3 of concrete
Sable (kg/ ma de béton) 360 461 Sand (kg / m a concrete) 360 461
Eau aj outée 100 150  Water added 100 150
Kg/ m3 de béton Kg / m 3 of concrete
Tableau 7  Table 7
1 m3 de mélange est préparé. 1 m 3 of mixture is prepared.
Les caractéristiques physiques mesurées sur les blocs de chemi nées durcis à l ' extérieur du moule obtenus à parti r des compositions C1 et C2 décrites dans le tableau 7 sont données ci -dessous (tableau 8) : The physical characteristics measured on the hardened outer casing blocks obtained from compositions C1 and C2 described in Table 7 are given below (Table 8):
Tableau 8 Les produits ainsi obtenus ne permettent pas d' obteni r des blocs de cheminée étanches à l ' air, même lorsque la quantité de granulats f ins qui permettent de rédui re la porosité est augmentée. .Exemple 5 : Procédé de fabrication de blocs allégés de di mension 100 mm*190mm*500mm Table 8 The products thus obtained do not provide airtight chimney blocks, even when the amount of aggregates used to reduce the porosity is increased. Example 5: Process for manufacturing light weight diapers 100 mm * 190mm * 500mm
Le procédé d' introduction des différents constituants dans le mélangeur à béton est identique à cel ui décrit dans l ' exemple 3. The method of introducing the various constituents into the concrete mixer is identical to that described in Example 3.
Deux différentes compositions ont ainsi été préparées et sont décrites dans le tableau 9 ci -dessous. Two different compositions have thus been prepared and are described in Table 9 below.
Tableau 9  Table 9
La teneur en agent moussant dans les compositions 6 et 7 représente respectivement 0, 3% en poids et 0,4% en poids de la masse totale des différents constituants. Les caractéristiques physiques mesurées sur les blocs durcis à l ' extérieur du moule obtenus à partir des compositions décrites dans le tableau 7 sont données ci -dessous (tableau 10) : The content of foaming agent in the compositions 6 and 7 represents respectively 0.3% by weight and 0.4% by weight of the total mass of the various constituents. The physical characteristics measured on the hardened blocks outside the mold obtained from the compositions described in Table 7 are given below (Table 10):
Tableau 10  Table 10
Ces essais montrent qu' il est possible selon le procédé de la présente invention d' obtenir des blocs al légés d' une masse volumique inférieure à 750 kg/ m3 et qui possèdent de bonne résistance mécanique à la compression. These tests show that it is possible according to the method of the present invention to obtain lightweight al blocks with a density of less than 750 kg / m 3 and which have good compressive strength.
.Exemple 6 : Procédé de fabrication de bl ocs de di mensions 100 mm*190mm*500mm Le procédé d' introduction des différents constituants dans le mélangeur à béton est identique à cel ui décrit dans l ' exemple 3. .Example 6: A method of manufacturing bl ocs di mensions 100mm * 190mm * 500mm The method of introducing the various constituents in the concrete mixer is identical to cel ui described in Example 3.
Une composition 8 a ai nsi été préparée et est décrite dans le tableau 1 1 ci- dessous. Composition 8 A composition 8a was prepared and is described in Table 11 below. Composition 8
Leca® rond 4-10 mm 285  Leca® round 4-10 mm 285
Kg/ m3 de béton Kg / m 3 of concrete
Ci ment EN 197-1 -CEM I 42.5 P 130  In accordance with EN 197-1 -CEM I 42.5 P 130
Norcem Industri Kg/ m3 de béton Norcem Industri Kg / m 3 concrete
Alcool polyvinyl ique B 2, 6  Polyvinyl alcohol B 2, 6
Kg/ m3 de béton Kg / m 3 of concrete
Eau aj outée 55  Water added 55
Kg/ m3 de béton Kg / m 3 of concrete
Total (Kg/ ma de béton) 473 Total (Kg / m has concrete) 473
Tableau 1 1  Table 1 1
La teneur en agent moussant dans la composition 8 représente 0, 5%en poids de la masse totale des différents constituants. The content of foaming agent in the composition 8 represents 0.5% by weight of the total mass of the various constituents.
Les caractéristiques physiques mesurées sur les blocs parpaings durcis à l ' extérieur du moule obtenus à partir de la composition 8 décrite dans le tableau 1 1 sont données ci -dessous (tableau 12) The physical characteristics measured on the hardened block blocks outside the mold obtained from the composition 8 described in Table 1 1 are given below (Table 12).
Tableau 12  Table 12
Cet essai montre que le procédé selon l ' invention permet de fabriquer des blocs très al légés à partir de granulats légers grossiers, qui gardent une résistance à la compression supérieure à 2 MPa. La densité de ce produit et les coûts de fabrication associés à ce produit sont nettement réduits. .Exemple 7 (comparatif) : blocs conventionnels This test shows that the process according to the invention makes it possible to produce high alum blocks light from coarse light aggregates, which keep a compressive strength greater than 2 MPa. The density of this product and the manufacturing costs associated with this product are significantly reduced. .Example 7 (comparative): conventional blocks
A titre de comparaison, des blocs standards de di mension 100mm*190mm*500 mm ont été fabriqués, avec un sable dont la densité en vrac est de 1200 kg/ m3 La composition est donnée dans le tableau 13. For comparison, standard blocks of di mension 100mm * 190mm * 500mm were manufactured, with a sand with a particle bulk density is 1200 kg / m 3 The composition is given in Table 13.
Tableau 13  Table 13
Les caractéristiques physiques mesurées sur les blocs parpaings durcis à l ' extérieur du moule obtenus à partir de la composition décrite dans le tableau 13 sont données ci -dessous (tableau 14) : The physical characteristics measured on the cured block blocks outside the mold obtained from the composition described in Table 13 are given below (Table 14):
Tableau 14.  Table 14.

Claims

REVENDICATIONS
Procédé de fabrication d'une composition de béton ou mortier allégé présentant une masse volumique à l'état sec comprise entre 200 et 1400 kg/ m3 caractérisé en ce qu'il comprend le mélange de constituants comprenant au moins des granulats légers de masse volumique de particules comprise entre 50 et 1000 kg/ m3, au moins un liant minéral choisi parmi les liants hydrauliques, les sources de sulfates de calcium et la chaux, au moins un agent moussant et de l'eau, et éventuellement un ou plusieurs additifs, le dit agent moussant étant un alcool polyvinylique et son moussage se faisant in-situ lors de son mélange avec l'eau et avec au moins un des constituants choisis parmi les granulats et/ ou le liant minéral. Process for manufacturing a composition of lightweight concrete or mortar having a density in the dry state of between 200 and 1400 kg/m 3 characterized in that it comprises the mixture of constituents comprising at least light aggregates of density of particles between 50 and 1000 kg/m 3 , at least one mineral binder chosen from hydraulic binders, sources of calcium sulfates and lime, at least one foaming agent and water, and optionally one or more additives , said foaming agent being a polyvinyl alcohol and its foaming taking place in situ during its mixing with water and with at least one of the constituents chosen from the aggregates and/or the mineral binder.
Procédé selon la revendication précédente caractérisé en ce que l'alcool polyvinylique a un degré d'hydrolyse compris entre 65 et 99 % molaire, de préférence entre 70 et 99 %molaire. Process according to the preceding claim, characterized in that the polyvinyl alcohol has a degree of hydrolysis of between 65 and 99 mol%, preferably between 70 and 99 mol%.
Procédé selon l'une des revendications précédentes caractérisé en ce que le mélange comprend en outre un agent moussant à base de tensioactif anionique, cationique, zwitterionique et/ ou non-ionique. Procédé selon des revendications 1 ou 2 caractérisé en ce que le mélange comprend uniquement un agent moussant constitué d'un ou pl usi eurs al cool s pol yvi nyl i ques. Method according to one of the preceding claims, characterized in that the mixture further comprises a foaming agent based on anionic, cationic, zwitterionic and/or non-ionic surfactant. Process according to claims 1 or 2, characterized in that the mixture comprises only a foaming agent consisting of one or more polyvinyl alcohols.
Procédé selon l'une des revendications 1 à 4 caractérisé en ce que la teneur en agent moussant représente entre 0,01% et 8%en poids du mélange total des différents constituants, de préférence entre 0,01%et 5% en poids et encore plus préférentiellement entre 0,05% et 2% en poids. Method according to one of claims 1 to 4 characterized in that the content of foaming agent represents between 0.01% and 8% by weight of the total mixture of the different constituents, preferably between 0.01% and 5% by weight and even more preferably between 0.05% and 2% by weight.
Procédé selon l'une des revendications précédentes caractérisé en ce que l'ajout de l'agent moussant est réalisé directement dans le mélangeur dans lequel la composition de mortier ou béton est préparée, l'agent moussant étant introduit soit sous forme de poudre sèche, soit sous forme d'une solution aqueuse. Method according to one of the preceding claims, characterized in that the addition of the foaming agent is carried out directly in the mixer in which the mortar or concrete composition is prepared, the foaming agent being introduced either in the form of a dry powder, either in the form of an aqueous solution.
7. Procédé selon la revendication 6 caractérisé en ce que les granulats allégés, l'eau et l'agent moussant sont mélangés ensemble dans le mélangeur, avant d'introduire le liant minéral. 7. Method according to claim 6 characterized in that the light aggregates, the water and the foaming agent are mixed together in the mixer, before introducing the mineral binder.
8. Procédé selon l'une des revendications précédentes caractérisé en ce que de l'eau chauffée est introduite dans le mélange de façon à obtenir une composition de béton ou mortier à une température de 20 à 25°C. 8. Method according to one of the preceding claims characterized in that heated water is introduced into the mixture so as to obtain a concrete or mortar composition at a temperature of 20 to 25°C.
9. Procédé selon l'une des revendications précédentes caractérisé en ce que les granulats allégés sont choisis parmi les argiles expansées, les schistes expansés, les pouzzolanes, les pierres ponces, les polystyrènes expansés, les cénosphères notamment de cendres volantes, le verre expansé, les laitiers concassés et broyés, la vermiculite ou la perlite, les granulats de liège broyé, les granulats de déchets de pneus broyés, possédant une masse volumique des particules comprise entre 50 et 1000 kg/ m3, de préférence entre 200 et 600 kg/ m3, leur teneur dans le mélange étant comprise entre 10 et 95%en poids, de préférence entre 30 et 95%en poids du mélange total des différents constituants. 9. Method according to one of the preceding claims characterized in that the light aggregates are chosen from expanded clays, expanded schists, pozzolans, pumice stones, expanded polystyrenes, cenospheres in particular from fly ash, expanded glass, crushed and ground slag, vermiculite or perlite, crushed cork aggregates, crushed tire waste aggregates, having a particle density of between 50 and 1000 kg/m 3 , preferably between 200 and 600 kg/ m 3 , their content in the mixture being between 10 and 95% by weight, preferably between 30 and 95% by weight of the total mixture of the different constituents.
10. Procédé selon l'une des revendications précédentes caractérisé en ce que le mélange comprend en outre des additifs qui sont des agents rhéologiques tels que les plastifiants ou les superplastifiants, des agents rétenteurs d'eau, des agents épaississants, des agents de protection biocides, des agents dispersants, des agents hydrofuges de masse, des pigments, des accélérateurs et/ ou retardateurs, et d'autres agents permettant d'améliorer la prise, le durcissement et/ ou la stabilité du mortier ou béton après application, d'ajuster la couleur, la maniabilité, la mise en œuvre ou l'imperméabilité. 10. Method according to one of the preceding claims characterized in that the mixture further comprises additives which are rheological agents such as plasticizers or superplasticizers, water retaining agents, thickening agents, biocidal protection agents , dispersing agents, mass water-repellent agents, pigments, accelerators and/or retarders, and other agents making it possible to improve the setting, hardening and/or stability of the mortar or concrete after application, to adjust color, handling, implementation or waterproofing.
11. Procédé selon l'une des revendications précédentes caractérisé en ce que le liant minéral est 11. Method according to one of the preceding claims characterized in that the mineral binder is
-un liant hydraulique choisi parmi les ciments Portland, les ciments alumineux, les ciments sulfoalumineux, les ciments bélitiques, les laitiers de haut fourneau, les ciments de mélange pouzzolaniques comprenant éventuellement des cendres volantes, des fumées de silice, du calcaire, du schiste calciné et/ ou des pouzzolanes naturelles ou calcinées, seuls ou en mélange, - une source de sulfate de calcium choisi parmi le plâtre ou hémi hydrate, le gypse et/ ou l ' anhydrite, et/ ou -a hydraulic binder chosen from Portland cements, aluminous cements, sulphoaluminous cements, belitic cements, blast furnace slag, pozzolanic mixture cements possibly comprising fly ash, silica fumes, limestone, calcined shale and/or natural or calcined pozzolans, alone or in mixture, - a source of calcium sulfate chosen from plaster or hemihydrate, gypsum and/or anhydrite, and/or
- de la chaux, - lime,
la teneur en l iant minéral représentant entre 5 et 40% en poids du mélange total des différents constituants. the mineral binder content representing between 5 and 40% by weight of the total mixture of the different constituents.
12. Composition de béton ou mortier al légé caractérisée en ce qu' el le est obtenue par le procédé selon l ' une des revendications 1 à 1 1. 12. Lightweight concrete or mortar composition characterized in that it is obtained by the process according to one of claims 1 to 1 1.
13. Produits de construction ayant une masse volumique à l ' état sec comprise entre 200 et 1400 kg/ m3, éventuel lement préfabriqués, tels que des blocs de maçonnerie, des blocs de chemi née, des dalles, des li nteaux, des panneaux ou des éléments de construction murale, obtenus après durcissement de la composition de béton ou mortier al légé selon la revendication 12. 13. Construction products having a dry density of between 200 and 1400 kg/ m3 , possibly prefabricated, such as masonry blocks, chimney blocks, slabs, lintels, panels or wall construction elements, obtained after hardening of the lightweight concrete or mortar composition according to claim 12.
14. Procédé de fabrication de produits préfabriqués selon la revendication 13 caractérisé en ce qu' il comprend une étape de moulage de la composition selon la revendication 1 1 , réalisée de préférence dans une machine vibrante de compactage de blocs ou dans tout autre dispositif de compactage équivalent automatique, dans laquel le ladite composition est versée ou extrudée dans un moule ou coffrage, par gravité et/ ou en appl iquant une force, i mmédiatement suivie par une étape de démoulage, et une étape de durcissement réal isée en dehors du moule. 14. Process for manufacturing prefabricated products according to claim 13 characterized in that it comprises a step of molding the composition according to claim 1 1, preferably carried out in a vibrating block compaction machine or in any other compaction device automatic equivalent, in which said composition is poured or extruded into a mold or formwork, by gravity and/or by applying force, immediately followed by a demolding step, and a hardening step carried out outside the mold.
15. Procédé de fabrication de produits préfabriqués selon la revendication 13 caractérisé en ce qu' i l comprend une étape de moulage de la composition selon la revendication 1 1 réalisée de préférence dans un dispositif de compactage automatique, dans laquel le ladite composition est versée ou extrudée dans un moule ou coffrage, par gravité et/ ou en appliquant une force, une étape de durcissement réal isée dans le moule, suivie par une étape de démoulage de la composition durcie. 15. Process for manufacturing prefabricated products according to claim 13 characterized in that it comprises a step of molding the composition according to claim 1 1 preferably carried out in an automatic compacting device, into which said composition is poured or extruded in a mold or formwork, by gravity and/or by applying force, a hardening step carried out in the mold, followed by a step of unmolding the hardened composition.
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