EP3972946A1 - Procédé de fabrication d'un béton cellulaire et d'un composant - Google Patents

Procédé de fabrication d'un béton cellulaire et d'un composant

Info

Publication number
EP3972946A1
EP3972946A1 EP20728703.8A EP20728703A EP3972946A1 EP 3972946 A1 EP3972946 A1 EP 3972946A1 EP 20728703 A EP20728703 A EP 20728703A EP 3972946 A1 EP3972946 A1 EP 3972946A1
Authority
EP
European Patent Office
Prior art keywords
cement
foam concrete
foam
producing
type
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.)
Pending
Application number
EP20728703.8A
Other languages
German (de)
English (en)
Inventor
Michael Anton Wolfgang WEBER
Ralf RÖDER
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.)
ARCCEN LTD.
Original Assignee
Weko Consulting And Engineering Ltd
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
Priority claimed from DE102019113570.2A external-priority patent/DE102019113570A1/de
Application filed by Weko Consulting And Engineering Ltd filed Critical Weko Consulting And Engineering Ltd
Publication of EP3972946A1 publication Critical patent/EP3972946A1/fr
Pending legal-status Critical Current

Links

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
    • 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
    • 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
    • C04B28/04—Portland 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
    • 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
    • C04B28/06—Aluminous cements
    • C04B28/065—Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
    • 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
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00146—Sprayable or pumpable mixtures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the invention relates to a method for producing a foam concrete.
  • Foam concrete is a concrete that is created by mixing a cement paste (which in particular contains cement and water) and a foam.
  • Foam concrete differs in this sense from aerated concrete, which is typically created by adding a blowing agent (e.g. aluminum powder) to the cement paste.
  • a blowing agent e.g. aluminum powder
  • the blowing agent leads to the foaming of the tough cement paste.
  • the invention solves the problem with the features of claim 1 and is accordingly characterized in that the cement used is a mixture which contains a first, preferably larger, proportion of a first type of cement, in particular a normal cement, and a second , preferably smaller, portion of a second type of cement, in particular a quick-release cement.
  • the idea of the invention is to produce foam concrete in a process in which two different types of cement or types of cement are used to produce the cement paste, namely in particular a conventional cement (or a conventional type of cement) and a special cement, namely in particular a quick-setting cement or a quick-setting cement Cement, used or mixed.
  • the rapid cement is particularly important here, since the use of (at least a portion) of this rapid cement ensures that the foam concrete hardens particularly quickly after the cement paste and foam have been mixed. In this way, it is prevented that the foam can break down or collapse excessively during the hardening process of the foam concrete. Overall, a higher strength or stability of the foam concrete produced is achieved as a result.
  • the applicant came up with the idea of improving the strength of the foam concrete by changing the properties of the cement used or the cement mixture used with regard to a particularly rapid setting time be adapted or optimized.
  • a certain reliability and an advantageous cost structure can be achieved through the use of conventional normal cement.
  • a cement as defined in EN 197 (-1) and / or DIN 1164 (as a type of normal cement) is regarded as normal cement.
  • a so-called 52.5 R cement applies as normal cement in this context (although any other combination from the group with the designation AB should also be considered normal cement, with A from group 32.5; 42.5 and 52 , 5 is selected and B from the group L, N or R; A relates to the so-called standard strength, B the so-called initial strength).
  • Portland cement can be regarded as normal cement within the meaning of the application.
  • a so-called special cement can in particular be selected as the second type of cement.
  • This is in particular a rapid cement, for example a so-called CSA cement.
  • Rapid cement is also known as lightning cement. This is a cement that sets particularly quickly. Mortars made from this type of cement usually have a working time of just a few minutes. However, cements with a processing time of up to one hour can also be regarded as rapid cement.
  • quick-setting cements can have high proportions of aluminum and / or calcium and / or sulfonate, for example.
  • CSA actually stands for calcium sulfo-aluminate cement in CSA cement.
  • This exemplary cement is a rapid cement that typically uses bauxite and / or limestone and / or gypsum as raw material.
  • quick-setting cements can be characterized by a high proportion of gypsum.
  • the CSA cement mentioned could also be viewed as a mixture between Portland and alumina cement.
  • a mixture of two types of cement is used as the cement, the proportion of the first type of cement being preferably greater than the proportion of the second type of cement.
  • the first type of cement with the greater proportion is typically normal cement and the second type of cement is special cement or rapid cement.
  • the production method for a foam concrete according to the present invention provides in particular that the cement paste is produced using water and cement.
  • the proportion of the provided by cement or by the cement mixture The total solids content of the cement paste is advantageously between 55% and 95%. All percentages in this patent application are to be understood as mass weight information.
  • the mixture of the (at least) two types of cement provided according to claim 1 thus makes up a proportion between 55% and 95% of the total solids which, in addition to the water, are used to produce the cement paste.
  • the proportion of the cement mixture in the total solids content of the cement paste is approximately between 65% and 92%.
  • the amount of the proportion also depends on the desired density of the cured foam concrete.
  • the method for producing the foam concrete comprises in particular the steps mentioned in claim 1, which do not necessarily have to take place in chronological order.
  • the cement paste is brought together with the foam, of course, after its respective production.
  • an additional mixture (a so-called “compound”) can be added during the production of the cement paste (which in any case takes place with the addition of water and cement) or (shortly) after it has been produced.
  • This “compound” serves in particular as an “alkali booster”, so it ensures a higher alkalinity of the cement paste and / or the foam concrete.
  • foam concrete which is also called aerated lightweight concrete or mineral foam
  • aerated concrete for aerated concrete on the other
  • the pores of aerated concrete components are connected to one another by a capillary system.
  • aerated concrete components Water to a considerable extent.
  • foam concrete on the other hand, the individual pores are (at least predominantly) separated from one another and not connected to one another. For this reason, foam concrete components, for example, cannot absorb any or almost no water.
  • foam concrete and aerated concrete are hardened under the influence of heat and pressure.
  • the foam concrete according to the invention typically hardens without the supply of heat and / or at atmospheric pressure.
  • the process according to the invention is in particular not carried out with the application of heat or pressure, for example in an autoclave.
  • heat or pressure for example in an autoclave.
  • the foam concrete according to the invention can typically have a dry bulk density of between 10 kg / m 3 and 300 kg / m 3 , in particular between 30 kg / m 3 and 190 kg / m 3 , for example about 120 kg / m 3 to 140 kg / m 3 3 .
  • the foam concrete is produced according to the invention by bringing together or mixing a cement paste with foam.
  • the foam is typically under the cement paste raised or the other way around. This is typically done in a mixing station, for example a mixing station in the manner of an agitator. Folding in or mixing is usually done at a low speed. This enables gentle mixing.
  • the mixing time can for example be between a few seconds and a few minutes, for example between 30 seconds and 5 minutes, more preferably between 1 and 2 minutes.
  • the foam required for this is typically generated in a separate foam unit and then fed to the mixing station.
  • the foam can of course also be produced in the mixing station itself, for example in the manner of a large basin.
  • the cement paste can be added successively or cyclically to the foam, which is then located in the mixing station, and lifted or mixed with an agitator.
  • the cement paste is also referred to as "slurry".
  • the stirring or folding in is advantageously carried out with a certain regularity, and new cement paste can be added continuously.
  • This is a known procedure, for example from the ice cream or Kaiserschmarrn production area. So preferably not all of the cement paste and all of the foam are already in the mixing station at the beginning of the stirring process.
  • an exemplary mixing station there are, for example, 750 to 800 liters of foam and 100 to 300 liters of cement paste in one cubic meter of the mixed mass.
  • the ratio mentioned can of course also be between 5: 1 and 20: 1, preferably between 3: 1 and 50: 1.
  • the mass produced in this way which can also be referred to as (liquid or viscous) foam concrete or foam concrete raw material, is then typically pumped out and further shaped or processed into a component.
  • the foam which is mixed with the cement paste to produce the foam concrete, typically consists of a composition of air and a foaming agent which has proteins and / or aluminum salts and / or surfactants and / or water.
  • the foaming agent is therefore typically liquid or in any case fluid.
  • the foaming agent is foamed with air to produce the foam, for which purpose the foaming agent is preferably added to an air space. This can be done using a foam generator, which then directly fills the mixing station itself with foam, or first a separate basin or the like, from which the foam is then fed to the mixing station.
  • the foaming agent and / or the foam and / or the foamed concrete advantageously contain lipids, in particular rhamnolipids.
  • the cement paste is taken, for example, from a colloid mixer, which is also referred to as a colloidal mixer.
  • Colloid or colloidal mixers are used, for example, in the production of suspensions with the smallest particles.
  • the breakdown of the particles i.e. the separation of clumps, is the focus.
  • Particle breakdown is aimed at, among other things, in order to increase the reactive surface area of the material.
  • any other suitable mixer can also be used, for example even a hand mixer or the like.
  • certain additives are used. In addition to the cement mixture, these additives are of course also
  • Metakaolin, microsilica, nanosilica, hydroxyapatite, trycalcium phosphate and / or pyrogenic silica, for example, can be used as additives.
  • the innovative foam concrete according to the invention opens up a large number of new areas of application due to its significant advantages over other thermal insulation materials (inexpensive, non-flammable, environmentally friendly, etc.).
  • the obvious development towards the replacement of Styrofoam and other known insulation materials requires an adaptation of the foam concrete to the specific requirement profiles of the component constructions (e.g. ETICS or thermal insulation of steep and flat roofs).
  • ETICS thermal insulation of steep and flat roofs
  • the foam concrete can also be used on the inner wall.
  • it is preferably shaped and, for example, sawn and / or cut in the manner of plates or blocks. It can then be used particularly advantageously as an insulation board, in particular with particularly low thermal conductivity properties.
  • the foam concrete, or that taken from the mixing station is processed further to form a component.
  • the process can also be considered to have been completed beforehand.
  • the further processing can in particular involve shaping and / or a drying process.
  • the not yet hardened foam concrete removed from the mixing station hardens in the autoclave.
  • the autoclave may or may not be used.
  • the foam concrete which is then still liquid or pulpy or viscous, should be placed in a mold in order to dry.
  • the shape can be a casing, for example.
  • the finished insulation board can then be designed in the form of blocks or plates.
  • that which has been removed from the mold can be sawn or cut to size or the like, for example in a plate shape.
  • that which has been removed from the mold can be sawn or cut to size or the like, for example in a plate shape.
  • several insulation panels can be worked out of a casing.
  • Other shapes for other components can of course also be easily implemented.
  • the foam concrete can also be made of another material, such as wood or stone or the like, existing element are entered, which then represents the finished component with the entered, dried foam concrete.
  • the component can also have materials other than foam concrete, in particular wood or stone or another type of concrete or the like, for example.
  • Portland cement is used as the first type of cement, in particular a Portland cement EN 197-1, preferably 32.5; 42.5 or 52.5
  • the CSA cement described above ie calcium sulfo-aluminate cement, is preferably used as the second type of cement.
  • the ratio of the first type of cement (e.g. normal cement) to the second type of cement (e.g. rapid cement) is between 1.5 and 4 or between 1.5: 1 and 4: 1.
  • the ratio is advantageously between 1.8 and 2.5, more preferably about 2: 1.
  • the cement for example the first and / or second type of cement
  • the cement is finely ground, for example after it has been mixed or before.
  • the grinding process can lead to a particle and / or grain size of on average less than 10 micrometers, further advantageously less than 5 micrometers, further advantageously between 1 and 4 micrometers (on average).
  • the grinding process can take place in a ball mill, for example.
  • Typical cement has a grain size of about 40 to 50 micrometers. According to the most preferred embodiment it is provided that the
  • Cement or cement paste contains an additive that increases the alkalinity, a so-called "compound”. This can ensure a particularly high alkalinity of the cement paste.
  • This additive or “compound” can therefore also be referred to as an “alkali booster”.
  • the mass of the additive can in particular correspond approximately to the mass of the cement type with the lower proportion, plus / minus 20 percent.
  • the mass of the “compound” can correspond to the mass of the quick-setting cement.
  • the ratio of the mass of the additive or “compound” to the cement mixture can therefore be roughly similar to that of the first type of cement (which has a larger proportion) to the second type of cement (which has a smaller proportion).
  • the ratio of cement mixture to “compound” can be between 2.5 and 5, for example.
  • the additive or “compound” can advantageously comprise sodium bicarbonate and / or potassium. These substances can be used, for example, in oxidic form or as hydroxide.
  • soda it can be in the form of caustic soda, powder, caustic soda or the like in the “compound”.
  • the “compound” can also have microselikia, as described elsewhere as an additive in this application.
  • a concrete liquefier or plasticizer is used in the production of the cement paste.
  • This can in particular be a so-called flow agent for concrete according to EN 934-2.
  • Such a substance can bring about advantageous properties in particular by reducing the surface tension of the water, for example strong plasticization of the foam concrete without introducing air pores into the concrete.
  • Fly ash can particularly advantageously be used in the production of the cement paste.
  • Very fine fly ash is preferably used, which according to the invention has in particular been subjected to an additional grinding process, for example in a (separate) or the same ball mill.
  • Fly ash is typically the solid, disperse (particulate, particulate, dusty) residue from burns.
  • fly ash cement can also be used as one of the types of cement, for example as the first type of cement, but in principle also.
  • the present invention relates to a method for producing a structural element made of foam concrete, comprising the following steps:
  • the foam concrete can in particular be further processed into an insulating board.
  • the present invention also relates to a recipe for a cement paste for the production of foam concrete according to claim 10, this cement paste having at least the following components: a) water, b) cement of a mixture which has a first, preferably larger, proportion a first type of cement, in particular a normal cement, and a second, preferably smaller, portion of a second type of cement, in particular a rapid cement.
  • a cement paste can be produced which can be used in one of the above-described methods for producing a foam concrete or a structural element.
  • a first advantageous embodiment provides that the proportion of cement, based on the total solids content of the cement paste, is at least 55%, advantageously at least 60%, further advantageously at least 70%, further advantageously at least 80%.
  • the proportion of anhydride based on the total solids content of the cement paste is at least 0.4%, preferably at least 0.5%, further advantageously at least 2%, further advantageously at least 5% or about 5 %.
  • the proportion of aluminum sulfate based on the total solids content of the cement paste is at least 0.4%, advantageously at least 0.5%, further advantageously at least 2%, further advantageously at least 5% or about 5%.
  • the present invention relates to a component, for example an insulating board, according to claim 11.
  • the invention relates to a method according to claim 12.
  • fly ash is mixed with cement, in particular quick-release cement (for example CSA cement), and this is used as a (cement) mixture, which then leads to the production of a cement paste for a foam concrete with the addition of water.
  • quick-release cement for example CSA cement
  • a cement paste is used with the following components:
  • Alkali Booster (“Compound”) approx. 10 kg, comprising approx. 50% anhydride and approx. 50% aluminum sulfate,
  • H 2 O water
  • foam preferably based on aluminum salts or proteins
  • the addition of superplasticizers ensures better product properties in the foam concrete.
  • cement (s) with a normal particle size of 40 to 50 micrometers are used, in particular with conventional normal cement as described above, but which is reduced or ground down to 2 to 3 micrometers by a further grinding process using, for example, a ball mill, in order to improve material properties in foam concrete.
  • the high-performance cement (especially based on Portland cement) achieved by grinding (in a ball mill or similar) shows better material properties in foam concrete.
  • ultra-fine fly ash or, depending on the case, ultra-fine ground fly ash in the ball mill or similar
  • the optional use of ultra-fine fly ash (or, depending on the case, ultra-fine ground fly ash in the ball mill or similar) in the foam concrete ensures better material properties in the foam concrete.
  • CO 2 emissions can also be reduced in the manufacture of the end product, foam concrete, in particular in comparison to conventional cement, the manufacture of which is CO 2 -intensive.
  • the invention relates to a component according to claim 13.
  • a component according to claim 13 Such a component has been produced according to the invention by a method according to claim 12.
  • the invention relates to a method according to claim 14.
  • the invention is in turn based on the object of specifying a method with which a structural element made of foam concrete can be provided with greater strength.
  • the invention solves the problem with the features of claim 14.
  • the cement comprises at least a portion of a rapid cement.
  • high strengths of the foam concrete can be achieved quickly in the manufacturing process.
  • the foam concrete and a correspondingly produced foam concrete element can dry very quickly and thus be made available for further processing.
  • the invention relates to a component according to claim 15.
  • the invention relates to a method according to claim 16. This invention is in turn based on the object described above.
  • the special feature of the invention according to claim 16 is that the cement and / or the cement paste used for the use in the method according to the invention according to claim 15 has portions of a compound mixture or that portions of the compound mixture are added to the cement and / or the cement paste will.
  • the special feature is that the compound mixture has at least the components anhydrite and aluminum sulfate.
  • An anhydrite is an anhydrous calcium sulfate in the customary definition. This is basically an extremely dry plaster of paris.
  • Anhydrite is also known as anhydrite spar, as a frequently occurring mineral from the mineral class of sulfates with the chemical composition Ca (SO 4 ).
  • the compound mixture has aluminum sulfate (Al 2 (SO 4 ) 3 ) as a further component.
  • the cement has the components anhydrite and aluminum sulfate in not insignificant amounts.
  • the compound mixture has only the two components anhydrite and aluminum sulfate. These two components can, for example, be present in approximately equal parts.
  • the invention also encompasses when the ratio of these two constituents is about 20:80, up to 30:70, and / or up to 40:60 or also 60:40, and / or up to 70:30 and / or 80:20 is.
  • the compound mixture can be added as a mixture of a cement type or a cement paste. However, it is also covered by the invention if several different types of cement are used in the process according to the invention according to the technical teaching of claim 1 and a corresponding compound mixture is added to such a mixture of several types of cement.
  • the invention also encompasses when the two constituents anhydrite and aluminum sulfate are not added as a prefabricated compound mixture to the cement or to the several types of cement or to the cement paste, but successively, i. H. at different times.
  • the decisive factor is that the two components anhydrite and aluminum sulfate are present in the cement or cement paste that is used in the method according to the invention.
  • the amount of the compound mixture added to the cement or cement paste can be approximately the same as the amount of a portion of a quick-release cement.
  • the anhydrite component and / or the aluminum sulfate component can each amount to about 1% to 30% by weight based on the total weight of the cement.
  • the invention recognizes that, as a result of the use of anhydrite, extremely rapid water absorption can take place, and in this way very rapid drying becomes possible. In this way, on the one hand, rapid processing of the component, but also particularly good strength of the component is achieved.
  • the invention also recognizes that the use of the aluminum sulfate component - in particular in combination with the anhydrite component - results in particularly homogeneous foaming.
  • the aluminum sulfate in combination and in the presence of anhydrite ensures extremely precise, homogeneous and optimized foaming during the manufacturing process.
  • the invention further recognizes that the surfaces of components produced by the method according to the invention have particularly good strength and, in particular, good processability, e.g. B. sawing, ensure.
  • the surfaces of the component produced by the method according to the invention are in particular also very dimensionally stable.
  • the components produced accordingly are not brittle, so that here, for. B. no material areas crumble.
  • the invention relates to a component according to claim 18.
  • the component produced according to the invention has at least one surface in particular a surface to which a deep base is applied.
  • a deep base is also referred to as an inlet base and is generally used in numerous areas in construction, e.g. B. as a primer for surfaces for the purpose of applying colors below, known.
  • the deep bottom can, for. B. be applied to the surface of the component in a spray process or in a dipping process.
  • the surface can be made harder and more grippy. In particular, this considerably reduces the surface flowability.
  • the material and mineral components that have not yet been sufficiently integrated into the solid structure by gluing or bonding during the manufacture of the component can adhere even better with the aid of the deep base.
  • the depth base means can also have an impregnation means.
  • FIG. 1 In the manner of a very schematic
  • Fig. 4 in a representation comparable to Fig. 1 in a schematic diagram of an embodiment of the invention in which a compound mixture is added to a cement or a cement mixture or a cement paste, which has at least the components anhydrite and aluminum sulfate, and
  • FIG. 5 shows another in a representation according to FIG
  • Embodiment of a method according to the invention in which the additives anhydrite or aluminum sulfate are added separately, in particular successively, to a cement or a cement mixture or a cement paste and the compound is only contained in the ready-mixed cement.
  • FIG. 1 initially shows a certain dichotomy: the production of a cement paste 20 is initially shown in the left half of FIG.
  • a cement mixture 12 is added to water 11, in particular with the addition of an additive 26 which can advantageously increase the alkalinity of the cement paste 20.
  • the cement mixture 12 contains two types of cement, namely a first type of cement 27 and a second type of cement 28.
  • first type of cement 27 is present in a larger proportion than the second type of cement 28, i.e. has a greater proportion by weight in the finished cement mixture 12 on.
  • the first type of cement 27 can in particular be a normal cement and / or the second type of cement 28 can be a special cement, for example a rapid cement.
  • the first type of cement 27 can be, for example, 32.5 or 42.5 or 52.5 normal cement act, especially R-cement (Rapid cement). Regardless of this, it can be a Portland cement, for example.
  • the second type of cement 28 can be provided, for example, by rapid cement, in particular so-called CSA cement.
  • the mixing of these two types of cement 27 and 28 can lead to an advantageous end product, concrete foam, or an advantageous structural element, in a manner to be described below.
  • the ratio of the two types of cement 27 and 28 to one another is approximately 2: 1 in the present exemplary embodiment, but can in principle be in the range of 1, 5: 1 and 4: 1, for example.
  • the cement mixture consists of about two thirds of the first cement type 27 and about one third of the second cement type 28.
  • the cement particles which typically have a size of 40 to 50 micrometers, can be reduced or ground down to (on average) 2 to 3 micrometers.
  • an alkalinity-increasing additive 26 a so-called “compound” or “alkali booster”, is also added to the mixer 19.
  • This additive 26 can in particular contain soda and / or potassium, preferably in oxidic form or as a hydroxide.
  • the soda can be used, for example, in the form of a lye or in powder form or as caustic soda.
  • the additive 26 can also contain microselects 15, as they could for example also be used as (separate) aggregate 13 and are described in more detail in connection with this.
  • FIG. 1 shows that the additive 26 is typically introduced into the mixer 19 together with the water 11 and the cement mixture 12.
  • a dashed line in FIG. 1 indicates that the additive 26 can alternatively be mixed with one of the two types of cement 27 or 28, in particular the first type of cement 27 or the second type of cement 28, even before being fed into the mixer 19.
  • the arrow also allows the possibility that the additive 26 can be mixed with the cement mixture 12 before this is introduced into the mixer 19 (and / or is ground in the mill 29).
  • the mill 29 or an additional or separate mill can also be used to finely grind fly ash (which in the present exemplary embodiment is optionally added to the mixer or is used to produce the cement paste 20).
  • a so-called superplasticizer is also shown in FIG. 1 with the reference numeral 30, which is also added to the mixer 19 or used to produce the cement paste 20.
  • Such a plasticizer can also be called a concrete plasticizer.
  • aggregates 13 may also be added (this is optionally possible, which is indicated by the dashed box).
  • additives can be metakaolin 14 and / or microsilica 15 and / or nanosilica 16 and / or hydroxyapatite 17 and / or trycalcium phosphate 18.
  • Plasticizer 30 and / or the additives 13 are then mixed in a mixer 19.
  • the components mentioned can either be transferred individually, for example one after the other, into the mixer, or they can be mixed together beforehand and transferred together into the mixer 19.
  • the mixer 19 is, in particular, a colloid mixer which in particular performs more than 1000 revolutions, preferably more than 2000 revolutions per minute. Colloid mixers are also called colloid mixers in technical terms.
  • the right-hand side according to FIG. 1 shows, purely schematically, the production of a foam 21 to be mixed with the cement paste 20.
  • air 22 is combined with a foaming agent 23 in a separate foam unit, not shown in FIG. 1, and in this way the foam 21 created.
  • the foaming agent 23 is foamed with the aid of the air 22, for example.
  • the foaming agent 23 is typically already in liquid form, in particular comprising (aluminum) salts and / or surfactants and / or proteins and / or water.
  • the foam 21 is produced and on the other hand the already mentioned cement paste 20, which is also referred to as “slurry”.
  • the foam 21 is now lifted under the cement paste 20 in a next step. This takes place in a preferably slowly rotating mixing station 24.
  • the mixing station 24 is in particular a mixing station which is separate from the mixer 19. This typically rotates much more slowly than the mixer 19. It can, for example, comprise a basin that is first filled with foam 21. A certain amount of cement paste 20 can then be added to this foam 21 successively or in a timed manner.
  • the mixing station 24 can include an agitator, which now regularly folds in the foam or folds the cement paste 20 into the foam.
  • the mixing ratio of foam 21 to liquid cement paste 20 or slurry can for example be between 5: 1 and 50: 1, preferably between 10: 1 and 20: 1, more preferably about 15: 1.
  • the mixing station 24 or the mentioned agitator can then mix the foam 21 and the cement paste 20, for example for less than 5 minutes, for example between half a minute and three minutes of mixing time.
  • the foam concrete can bond very quickly or solidify very quickly, namely before the foam sets 21 begins to change during the mixing process, for example to fall in or to change its properties or the like. In this way, it is also possible to counteract a lack of strength in the foam concrete obtained or the foam concrete that can be removed from the mixing station.
  • alkaline-increasing additive 26 is contained in the cement paste 20.
  • its high alkalinity ensures that the foam concrete mixture or foam concrete solidifies more quickly (before the foam can change too much).
  • a foam concrete mass is achieved in the mixing station 24, which (possibly after later curing) has a consistency that has a higher stability or strength in relation to the masses that are achieved according to the prior art.
  • the method shown can also protect the environment, at least in comparison to conventional cement, the production of which, for example, is relatively C - intensive.
  • the amount to be removed from the mixing station 24 can either be further processed directly at 25 or, according to an alternative embodiment of the method according to the invention, can first be transferred (once) to a (different or the already known) mixer 19 .
  • the subsequent further processing takes place at 25 to a finished component 10 then finally.
  • This further processing can in particular consist in pouring the mass (also called liquid or viscous foam concrete) removed from the mixing station 24, which may have been introduced into the mixer 19 ', into molds or blocks. This can then take place in a production plant or production line or on a construction site.
  • the shape or the block can then be stripped out and the shaped, dried mass made of the desired foam concrete material can be shaped, for example by sawing or cutting or dividing or the like.
  • a corresponding product can be sawn to size, in the form of a plate, which can then be used as an insulation board.
  • FIG. 3 shows an alternative method to the method illustrated in particular in FIG. 1.
  • a mixture 34 of fly ash 3T and a type of cement 28 ′ is fed into the mixer 19.
  • the type of cement 28 ′ can in particular be the same type of cement 28 that is shown in FIG. 1 was designated as the second type of cement 28, so for example a rapid cement, in particular a CSA cement.
  • FIG. 3 is only to be understood as a detail and is intended to replace the area mentioned in FIG. 1. All other special features and configurations according to FIG. 1 or 2 should follow this section of a schematic view according to FIG. 3 (for example the entire right-hand part relating to the foam and / or a mill 29 into which the mixture 34 could be input, or of course the water 11, the alkalinity-increasing additive 26 or the plasticizer 30 or the additives 13). In this respect, there are no other differences between the section according to FIG. 3 and the corresponding section in FIG. 1. The addition of fly ash 31, as indicated in FIG. 1, would then generally no longer be necessary.
  • a compound 100 can be added to a cement mixture 12 or a cement 12 according to the invention, in accordance with method claim 16.
  • the compound contains at least the components anhydrite and aluminum sulfate.
  • the compound is denoted by the reference symbol 100.
  • the arrow 101 comprises the method variant, according to which the compound 100 is fed directly to the cement 12 or the cement mixture 12 before it reaches the mixer 19.
  • a process variant makes it clear, according to the broken process-step line 102, that the compound can, however, also be introduced directly into the mixer 19 and only there can be mixed with the cement or the cement mixture. At this In a process variant, the compound 100 is thus fed to the cement paste 20 which is produced in the mixer 19.
  • the cement 12 or the cement mixture 12 is not supplied with a compound 100, but rather the anhydrite component 103 and the aluminum sulfate component 104 separately.
  • the two components anhydrite 103 and aluminum sulfate 104 can be fed in simultaneously or successively.
  • the component anhydrite can be added directly to the cement or cement mixture 12 according to the process arrow 105 or the component aluminum sulfate 104 can be added directly to the cement or the cement mixture 12 according to the process arrow 106 or alternatively the component anhydrite 103 according to the process arrow 107 and / or the component aluminum sulfate 104 according to the process arrow 108 is fed directly to the mixer 19 and only mixed there with the cement or cement mixture 12, i.e., more precisely, with the cement paste 20 formed in the mixer 19 can be.

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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)

Abstract

L'invention concerne entre autres un procédé de fabrication d'un béton cellulaire, comprenant par exemple des étapes suivantes consistant à : fabriquer une pâte de ciment en utilisant de l'eau et du ciment ; fabriquer une mousse à partir d'air et d'un agent moussant et réunir la pâte de ciment et la mousse en particulier dans une station de mélange ; et mélanger les deux constituants pour former un béton cellulaire. L'invention est caractérisée en ce qu'est utilisé en tant que ciment un mélange, lequel comporte une première fraction, de préférence plus grande, d'un premier type de ciment, en particulier d'un ciment normal et une deuxième fraction, de préférence inférieure, d'un deuxième type de ciment, en particulier d'un ciment rapide.
EP20728703.8A 2019-05-21 2020-05-22 Procédé de fabrication d'un béton cellulaire et d'un composant Pending EP3972946A1 (fr)

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DE102019113570.2A DE102019113570A1 (de) 2019-05-21 2019-05-21 Verfahren zur Herstellung eines Schaumbetons und eines Bauelements
DE202020100170 2020-01-14
PCT/EP2020/064299 WO2020234462A1 (fr) 2019-05-21 2020-05-22 Procédé de fabrication d'un béton cellulaire et d'un composant

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CN115784678B (zh) * 2022-10-13 2024-01-19 北京超薪创艺科技有限公司 一种自密实烧结轻集料发泡混凝土的制备方法

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US4057608A (en) * 1976-04-19 1977-11-08 Showa Denko Kabushiki Kaisha Process of continuous manufacture of light-weight foamed concrete
US10040725B2 (en) * 2016-07-19 2018-08-07 United States Gypsum Company Lightweight foamed cement, cement board, and methods for making same
DE102017129140A1 (de) 2016-12-10 2018-06-14 Chris Ralf Röder Verfahren zur Herstellung eines Bauelementes aus Schaumbeton und selbiges
CN107324735B (zh) * 2017-07-13 2020-01-03 重庆大学 一种超轻泡沫混凝土及其制备方法

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