EP4118057A1 - Manufacture of a wall by dry spraying of a composition comprising unbaked earth - Google Patents

Manufacture of a wall by dry spraying of a composition comprising unbaked earth

Info

Publication number
EP4118057A1
EP4118057A1 EP21710515.4A EP21710515A EP4118057A1 EP 4118057 A1 EP4118057 A1 EP 4118057A1 EP 21710515 A EP21710515 A EP 21710515A EP 4118057 A1 EP4118057 A1 EP 4118057A1
Authority
EP
European Patent Office
Prior art keywords
weight
binder
composition
slag
aggregates
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
EP21710515.4A
Other languages
German (de)
French (fr)
Inventor
Nicolas Royer
Jean-Claude BURTIN
Michel CRESPEL
Lionel Raynaud
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 EP4118057A1 publication Critical patent/EP4118057A1/en
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
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/06—Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
    • C04B40/0608—Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
    • 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
    • C04B28/001—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 unburned clay
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—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
    • C04B28/08—Slag cements
    • C04B28/082—Steelmaking slags; Converter slags
    • 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
    • C04B2111/00155—Sprayable, i.e. concrete-like, materials able to be shaped by spraying instead of by casting, e.g. gunite
    • C04B2111/00163—Sprayable, i.e. concrete-like, materials able to be shaped by spraying instead of by casting, e.g. gunite by the dry process
    • 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
    • Y02P40/18—Carbon capture and storage [CCS]
    • 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

  • Manufacture of a wall by dry spraying of a composition comprising raw earth The invention relates to the field of construction.
  • It relates more particularly to the construction of walls, in particular of walls, of buildings.
  • the walls are made of concrete, which is prepared in concrete plants, then transported to the site in mixer trucks and finally poured between formwork. The concrete then ensures both the bearing of the building and the realization of the wall by filling.
  • the load-bearing structure of the building consists of frame parts (for example of the column and beam type), often in concrete, prefabricated in the factory and transported by truck to the site, the infill wall being produced at the site. by means of concrete blocks or bricks (generally in terracotta) assembled by mortars or glues.
  • prefabricated concrete walls are transported by truck to the site and fixed to the supporting structure of the building.
  • These different construction techniques due to the materials used and their implementation, have a high environmental footprint, both by greenhouse gas emissions and by consumption of abiotic resources, and thus contribute to the depletion of the latter. as well as global warming.
  • Cement production requires the extraction of limestone and clays and, due to the high temperatures required during heating, produces large amounts of CO2 (approx. 800 kg per tonne of cement produced). Concrete production also requires the extraction of various sands and aggregates.
  • the transport (usually road) of prefabricated construction materials to construction sites also contributes to global warming. Finally, construction generates significant volumes of excavation waste.
  • Application WO 96/11309 discloses a method for manufacturing walls comprising the dry spraying of a composition comprising a binder and raw earth.
  • the binder is Portland cement or a pozzolanic material such as fly ash.
  • the aim of the invention is to improve this technique by proposing a construction technique with a reduced environmental footprint, as well as compositions suitable for this technique, which make it possible to obtain walls which meet the requirements of the field in terms of quality.
  • the invention relates to a process for obtaining a wall, in which a filling wall is produced between frame parts by dry spraying of a pulverulent composition
  • a pulverulent composition comprising:
  • binder from 1 to 40% by weight of binder, including slag, the proportion by weight of slag relative to the total weight of binder being at least 30%,
  • the wall can be an infill wall, therefore non-structural. It can also be a structural wall.
  • a subject of the invention is a wall obtained (or capable of being obtained) by implementing such a method.
  • a subject of the invention is a pulverulent composition suitable for use in the process according to the invention, which comprises:
  • binder from 1 to 40% by weight of binder, including slag, the proportion by weight of slag relative to the total weight of binder being at least 30%,
  • Dry spraying is a technique in which a pulverulent composition is propelled, in particular by compressed air, along a pipe towards a spray lance, water (generally under pressure) being added to the composition. in the lance in order to ensure the humidification of the composition just at the moment of projection.
  • This technique is used today in new work or (especially) in repairing old structures to project layers of concrete onto a support coated with reinforcements. It is mainly used to produce very complex shapes or for sites that are difficult to access (tunnels, underground works, etc.).
  • the inventors have been able to demonstrate that such a technique could be used to produce walls exhibiting good mechanical strength and good durability, from a pulverulent composition comprising raw earth and a binder based on slag.
  • the use of raw land makes it possible both to reduce greenhouse gas emissions and the depletion of abiotic resources.
  • the raw earth is preferably obtained from the excavation of soils located on the site or near the site, so that it requires little or no transport.
  • the raw earth can come from neighboring sites, for example from public works sites (construction of tunnels for underground means of transport, etc.). The process therefore makes it possible to recycle this excavated soil (thus reducing the waste generated by the site) and to reduce the need for concrete or prefabricated materials as well as their transport.
  • slag compared to Portland cement or pozzolanic materials, makes it possible to reduce dimensional variations of thermal origin, and therefore the risk of the appearance of cracks. This property could be due to the fact that the heat released during the hydration reaction is lower.
  • the long-term mechanical strength and durability of the material constituting the wall are also better in the case of the use of slag, probably because its microstructure is less permeable to aggressive agents.
  • the wall can be an exterior or interior wall of a building.
  • the framework parts preferably have a supporting function. These are, for example, posts and beams, in particular in concrete (generally reinforced), in wood or in metal (in particular in steel).
  • the frame pieces are assembled in such a way as to create the load-bearing frame of the building, ensuring its rigidity and stability.
  • the pulverulent composition is preferably propelled by compressed air towards a spray lance.
  • the composition is dry in the sense that it is not mixed with the mixing water to form a paste. Some constituents of the composition, especially soil, may however be slightly wet.
  • the percentage of humidity of the pulverulent composition generally does not exceed 15%, in particular 10% and even 5% by weight. Water is added to the composition in the lance or near the lance, so to ensure the humidification of the composition just at the time of projection or just before it.
  • At least one retaining element is preferably placed between the frame pieces so as to retain the projected composition.
  • This retaining element is preferably in the form of a panel or a plate, in particular based on wood (for example of the OSB panel type), of metal or of plaster (for example of the plasterboard type), or else in the form of a close-knit fabric or mesh.
  • the retaining element is removed after completion of the wall.
  • the retaining element remains in place to form part of the wall of the building.
  • the wall according to the invention therefore comprises in this case the retaining element.
  • the holding element is plasterboard, this option is preferred.
  • the thickness of the wall obtained is preferably between 10 and 30 cm, in particular between 12 and 25 cm, for example close to 15 cm. It is therefore indeed a wall (self-supporting) and not a coating deposited on a pre-existing wall.
  • the process according to the invention uses a pulverulent composition comprising raw earth and a binder based on slag.
  • a pulverulent composition comprising raw earth and a binder based on slag.
  • the following details relate to this powdery composition.
  • binder content in the composition is between 1 and 40%, in particular between 2 and 30%, or even between 4 and 20% or alternatively between 5 and 15%, relative to the weight of pulverulent composition.
  • binder is meant a single binder or a mixture of binders. In the latter case, the term “binder” collectively covers this mixture, and the proportions indicated with respect to the binder take into account the total weight of binder.
  • the binder serves, in the final wall, to bind the aggregates so as to form a rigid material having sufficient mechanical strength.
  • the binder of the powder composition comprises a slag.
  • the proportion by weight of slag relative to the total weight of binder is at least 30%, in particular at least 40%, or even at least 50% or at least 60% or even at least 70% . This proportion may be 100%, in the sense that the binder consists of one (or more) slag (s), or at most 95% or at most 90%.
  • a slag is a by-product of an industrial process involving the fusion of a starting material, fusion intended to separate metals from an oxide phase, the latter being called “slag”.
  • the use of slag makes it possible to reduce the carbon footprint of the composition, and therefore of the process, in comparison with the use of a cement.
  • the slag is preferably granulated, in the sense that it has undergone thermal quenching with water, the consequence of which is to obtain grains which are generally predominantly amorphous.
  • the granulated slag is then preferably ground in order to make it more active.
  • the slag is therefore preferably a ground granulated slag.
  • the slag is a ground granulated blast furnace slag.
  • a slag used as a binder, has the advantage of being insensitive to external sulphate attack, which is advantageous in particular if the raw earth contains calcium sulphates.
  • the slag (in particular ground granulated blast furnace slag) is preferably activated.
  • the binder then comprises, in addition to the slag, an activator.
  • activator is meant here an activating compound (which improves the setting and / or hardening of the slag) or, collectively, a mixture of such compounds.
  • the total proportion of activator in the binder is preferably between 1 and 20%, in particular between 2 and 15% by weight.
  • the activator is preferably chosen from the group formed by: bases (in particular alkali metal hydroxides, alkali metal silicates and alkali metal carbonates); microparticles of slag with a fineness greater than or equal to 6000 Blaine; microparticles of calcium and / or magnesium carbonate, calcium silicate hydrates or aluminum silicate hydrates; ground aluminous granulated slags; sources of calcium sulphate (especially gypsum, hemihydrate or anhydrite); alkali metal sulfates, halides, nitrates or carboxylates; Portland cement; lime; and mixtures of two or more of these compounds.
  • bases in particular alkali metal hydroxides, alkali metal silicates and alkali metal carbonates
  • microparticles of slag with a fineness greater than or equal to 6000 Blaine microparticles of calcium and / or magnesium carbonate, calcium silicate hydrates or aluminum silicate hydrates
  • the activator comprises slag microparticles with a fineness greater than or equal to 6000 Blaine, in particular between 6000 and 15000 Blaine, in a content of between 1 and 35%, in particular between 5 and 15% , weight of binder.
  • the activator can also comprise at least one of the following compounds: a base, in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 1%, in particular comprised between 0.2 and 0.4%, relative to the weight of binder; a source of calcium sulfate; alkali metal sulphates, in a total content of at most 1%, in particular between 0.2 and 0.4%, based on the weight of binder; Portland cement, an aluminous cement or a sulphoaluminous cement, in a total content of not more than 4% relative to the weight of binder.
  • a base in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 1%, in particular comprised between 0.2 and 0.4%, relative to the weight of binder
  • a source of calcium sulfate alkali metal sulphates, in a total
  • the activator comprises microparticles of calcium and / or magnesium carbonate, calcium silicate hydrates or aluminum silicate hydrates, the BET (nitrogen) specific surface of which is greater than 1 m 2 / g and the average diameter is less than 5 ⁇ m.
  • the activator can also comprise at least one of the following compounds: a base, in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 1%, in particular comprised between 0.2 and 0.4%, relative to the weight of binder; a source of calcium sulfate; alkali metal sulphates, in a total content of at most 1%, in particular between 0.2 and 0.4%, relative to the weight of binder; calcium nitrate, calcium formate, Portland cement, an aluminous cement or a sulphoaluminous cement, in a total content of not more than 5% relative to the weight of binder.
  • a base in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 1%, in particular comprised between 0.2 and 0.4%, relative to the weight of binder
  • a source of calcium sulfate alkali metal
  • the activator comprises a ground granulated aluminous slag, in particular the chemical composition of which comprises 30 to 60% by weight of alumina, 5 to 25% by weight of silica and 20 to 40% of lime. , alumina being the most abundant constituent.
  • the ground granulated aluminous slag is preferably obtained from the recycling by total melting of catalysts used for the desulphurization of petroleum products, in particular of catalysts based on molybdenum and / or cobalt.
  • the activator can also comprise at least one of the following compounds: a base, in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 2% relative to the weight of binder; a source of calcium sulfate; sulphates alkali metals, in a total content of at most 2% relative to the weight of binder; Portland cement, an aluminous cement or a sulphoaluminous cement, in a total content of not more than 2% relative to the weight of binder.
  • a base in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 2% relative to the weight of binder
  • a source of calcium sulfate sulphates alkali metals, in a total content of at most 2% relative to the weight of binder
  • Portland cement, an aluminous cement or a sulphoaluminous cement
  • a slag is a latent hydraulic binder, that is to say a binder whose hydraulic character can be obtained by adding at least one activator.
  • hydraulic binder is meant a binder which sets and hardens under water.
  • the activator is part of the binder and the total activator content is included in the total binder content.
  • the binder can further include other hydraulic binders, in addition to slag.
  • the or each (additional) hydraulic binder is preferably chosen from the group formed by Portland cements, belitic cements, aluminous cements, sulphoaluminous cements, pozzolanic mixture cements, fly ash, metakaolins, hydraulic lime and mixtures of two or more of these hydraulic binders.
  • Fly ash and metakaolins are pozzolanic binders which require activation by a lime source. In this case the lime source is part of the binder.
  • the total proportion by weight of Portland cement, aluminous cement, sulphoaluminous cement, hydraulic lime and aerial lime relative to the total weight of binder is preferably at most 20%, in particular d 'at most 10% and even at most 5%. This proportion is even advantageously zero.
  • the aggregate content in the composition is between 60 and 99%, in particular between 70 and 98%, or even between 80 and 96%, or alternatively between 85 and 95%, relative to the weight of pulverulent composition.
  • Aggregates include raw earth.
  • Raw earth typically contains sands, clays and silt, in varying amounts depending on where it is excavated.
  • the excavation site is located on the construction site or nearby so as not to negatively impact the environmental footprint of the process and reduce the amount of waste generated by the site.
  • the proportion by weight of raw earth relative to the total weight of aggregates is at least 50%, in particular at least 60% and even at least 70% or at least 80%. It can even be 100%, i.e. the aggregates consist of raw earth.
  • the raw earth may also have undergone preparatory operations for the implementation of the method, in particular but not only a screening operation.
  • preparation operations are carried out, they are preferably carried out at the site of excavation, the latter preferably being the site of construction.
  • the method according to the invention can therefore comprise a step of screening the raw earth prior to the projection step.
  • a drying step can also be carried out if necessary.
  • the aggregates can also comprise aggregates other than raw earth, and in particular lightweight aggregates and / or fibers.
  • Lightweight aggregates make it possible to reduce the density of the material constituting the wall, and therefore its weight, thereby making it possible to reduce the weight, and therefore the environmental footprint, of the structural parts of the building.
  • the presence of light aggregates also makes it possible to reduce the modulus of elasticity as well as the thermal conductivity of the final material.
  • the light aggregates preferably have a bulk density of at most 900 kg / m 3 , preferably between 50 kg / m 3 and 900 kg / m 3 , and in particular between 150 kg / m 3 and 800 kg / m 3 .
  • the bulk density of light aggregates can in particular be measured according to standard EN 1097-3: 1998.
  • the light aggregates are preferably chosen from pozzolan, perlite, vermiculite, expanded glass beads, hollow glass microspheres, cenospheres, expanded silicates, expanded clays, expanded polystyrene beads, cork and theirs. mixtures.
  • the light aggregates are of natural origin, for example pozzolans.
  • the proportion by weight of light aggregates relative to the total weight of aggregates is preferably at most 50%, in particular at most 40%, for example between 1 and 50%, in particular between 5 and 35%.
  • the fibers are preferably natural fibers (plant or animal), in particular plant fibers, such as hemp, flax or wood fibers.
  • the fibers allow the material to be mechanically reinforced.
  • the proportion by weight of fibers relative to the total weight of aggregates is preferably at most 10%, in particular at most 5%, for example between 1 and 10%, especially between 2 and 8%.
  • the pulverulent composition may also comprise, in addition to the binder and aggregates, various additives or adjuvants, chosen in particular from rheological agents, water-retaining agents, air-entraining agents, thickening agents, protection biocides, dispersing agents, pigments, accelerators and / or retarders, polymeric resins.
  • additives or adjuvants chosen in particular from rheological agents, water-retaining agents, air-entraining agents, thickening agents, protection biocides, dispersing agents, pigments, accelerators and / or retarders, polymeric resins.
  • the total content of additives and adjuvants preferably varies between 0.001 and 5% by weight relative to the total weight of the composition.
  • the pulverulent composition can comprise between 4 and 20% of a binder and between 80 and 96% of aggregates, the proportion of ground granulated blast furnace slag relative to the weight of binder being between 70 and 100% and the proportion of raw earth relative to the weight of aggregates being between 60 and 100%.
  • the maximum diameter (Dmax), determined by sieving is preferably at most 20 mm, in particular at most 16 mm.
  • the composition is not too fine, so that the coarser aggregates compact the fine particles of the composition and thus promote the adhesion of the material to the holding member.
  • the particle size distribution of the composition is such that the proportion of particles having a size between 8 and 16 mm, in particular between 10 and 16 mm, is at least 10% by weight, preferably between 10% and 30 % in weight. The particle size distribution is determined by sieving.
  • Example 1 is a comparative example not using slag.
  • the slag was a ground granulated blast furnace slag.
  • the aluminous slag was a ground granulated aluminous slag, resulting from the recycling by total melting of catalysts for the desulphurization of petroleum products based on cobalt and molybdenum.
  • the main constituents of this slag are alumina (41%), lime (32.6%), silica (12.6%), magnesium oxide (8.9%), iron oxide (1.6%) and sulfur (1.6%). Walls were obtained by dry spraying of these compositions between timber frames, against OSB retaining elements.
  • the thickness of the walls obtained was 9.5 cm, 14.5 cm and 18 cm.
  • the material After spraying, the material was set immediately after application and hard to the touch after 2 to 24 hours.
  • the drying, the acquisition of the mechanical properties and the possibility of covering (by a coating) then depend on various factors such as the humidity of the composition used, the thickness of application and the climatic conditions.

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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)
  • Dispersion Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Ceramic Products (AREA)

Abstract

The invention relates to a method for obtaining a partition, wherein a wall is produced by filling between the framework parts by dry spraying of a powdered composition comprising: - 1 to 40% by weight of binder, including slag, the proportion by weight of slag with respect to the total weight of binder being at least 30%; and - from 60 to 99% by weight of aggregates, including unbaked earth, the proportion by weight of unbaked earth with respect to the total weight of the aggregates being at least 50%.

Description

Fabrication d'un mur par projection par voie sèche d'une composition comprenant de la terre crue L'invention se rapporte au domaine de la construction. Manufacture of a wall by dry spraying of a composition comprising raw earth The invention relates to the field of construction.
Elle concerne plus particulièrement la construction de parois, notamment de murs, de bâtiments. It relates more particularly to the construction of walls, in particular of walls, of buildings.
Il existe aujourd'hui différentes techniques pour construire les murs d'un bâtiment, qu'il soit à usage résidentiel ou tertiaire. Dans une technique constructive connue, les murs sont constitués de béton, lequel est préparé dans des centrales à béton, puis transporté sur le chantier dans des camions toupie et enfin coulé entre des banches. Le béton assure alors à la fois le portage du bâtiment et la réalisation du mur par remplissage. Dans une autre technique connue, la structure porteuse du bâtiment est constituée de pièces d'ossatures (par exemple du type poteaux et poutres), souvent en béton, préfabriquées en usine et transportées par camion sur le chantier, le mur de remplissage étant réalisé au moyen de parpaings ou de briques (généralement en terre cuite) assemblés par des mortiers ou des colles. Selon une autre technique, des murs préfabriqués en béton sont transportés par camion sur le chantier et fixés sur la structure porteuse du bâtiment. Ces différentes techniques constructives, du fait des matériaux employés et de leur mise en œuvre, présentent une empreinte environnementale élevée, à la fois par émission de gaz à effet de serre et par consommation de ressources abiotiques, et contribuent ainsi à la déplétion de ces dernières ainsi qu'au réchauffement climatique. La production de ciment nécessite l'extraction de calcaire et d'argiles et, du fait des températures élevées requises lors du chauffage, produit de grandes quantités de CO2 (environ 800 kg par tonne de ciment produite). La production de béton exige en outre l'extraction de sables et granulats divers. Le transport (généralement routier) des matériaux de construction préfabriqués sur les chantiers contribue également au réchauffement climatique. Enfin, la construction génère des volumes importants de déchets d'excavation . Today there are different techniques for constructing the walls of a building, whether it is for residential or tertiary use. In a known construction technique, the walls are made of concrete, which is prepared in concrete plants, then transported to the site in mixer trucks and finally poured between formwork. The concrete then ensures both the bearing of the building and the realization of the wall by filling. In another known technique, the load-bearing structure of the building consists of frame parts (for example of the column and beam type), often in concrete, prefabricated in the factory and transported by truck to the site, the infill wall being produced at the site. by means of concrete blocks or bricks (generally in terracotta) assembled by mortars or glues. According to another technique, prefabricated concrete walls are transported by truck to the site and fixed to the supporting structure of the building. These different construction techniques, due to the materials used and their implementation, have a high environmental footprint, both by greenhouse gas emissions and by consumption of abiotic resources, and thus contribute to the depletion of the latter. as well as global warming. Cement production requires the extraction of limestone and clays and, due to the high temperatures required during heating, produces large amounts of CO2 (approx. 800 kg per tonne of cement produced). Concrete production also requires the extraction of various sands and aggregates. The transport (usually road) of prefabricated construction materials to construction sites also contributes to global warming. Finally, construction generates significant volumes of excavation waste.
On connaît de la demande WO 96/11309 un procédé de fabrication de parois comprenant la projection par voie sèche d'une composition comprenant un liant et de la terre crue. Le liant est du ciment Portland ou un matériau pouzzolanique tel que des cendres volantes. Application WO 96/11309 discloses a method for manufacturing walls comprising the dry spraying of a composition comprising a binder and raw earth. The binder is Portland cement or a pozzolanic material such as fly ash.
L'invention a pour but d'améliorer cette technique en proposant une technique constructive dont l'empreinte environnementale est réduite ainsi que des compositions adaptées à cette technique, qui permettent d'obtenir des murs répondant aux exigences du domaine en termes de qualité. The aim of the invention is to improve this technique by proposing a construction technique with a reduced environmental footprint, as well as compositions suitable for this technique, which make it possible to obtain walls which meet the requirements of the field in terms of quality.
Pour ce faire, l'invention a pour objet un procédé d'obtention d'une paroi, dans lequel on réalise un mur de remplissage entre des pièces d'ossature par projection par voie sèche d'une composition pulvérulente comprenant :To do this, the invention relates to a process for obtaining a wall, in which a filling wall is produced between frame parts by dry spraying of a pulverulent composition comprising:
- de 1 à 40% en poids de liant, dont du laitier, la proportion pondérale de laitier par rapport au poids total de liant étant d'au moins 30%, - from 1 to 40% by weight of binder, including slag, the proportion by weight of slag relative to the total weight of binder being at least 30%,
- de 60 à 99% en poids de granulats, dont de la terre crue, la proportion pondérale de terre crue par rapport au poids total de granulats étant d'au moins 50%. - from 60 to 99% by weight of aggregates, including raw earth, the proportion by weight of raw earth relative to the total weight of aggregates being at least 50%.
Le mur peut être un mur de remplissage, donc non- structurel. Il peut aussi être un mur structurel. The wall can be an infill wall, therefore non-structural. It can also be a structural wall.
L'invention a aussi pour objet une paroi obtenue (ou susceptible d'être obtenue) par la mise en œuvre d'un tel procédé. L'invention a enfin pour objet une composition pulvérulente apte à être utilisée dans le procédé selon l'invention, qui comprend : Another subject of the invention is a wall obtained (or capable of being obtained) by implementing such a method. Finally, a subject of the invention is a pulverulent composition suitable for use in the process according to the invention, which comprises:
- de 1 à 40% en poids de liant, dont du laitier, la proportion pondérale de laitier par rapport au poids total de liant étant d'au moins 30%, - from 1 to 40% by weight of binder, including slag, the proportion by weight of slag relative to the total weight of binder being at least 30%,
- de 60 à 99% en poids de granulats, dont de la terre crue, la proportion pondérale de terre crue par rapport au poids total de granulats étant d'au moins 50%. - from 60 to 99% by weight of aggregates, including raw earth, the proportion by weight of raw earth relative to the total weight of aggregates being at least 50%.
La projection par voie sèche est une technique dans laquelle une composition pulvérulente est propulsée, notamment par de l'air comprimé, le long d'une tuyauterie vers une lance de projection, de l'eau (généralement sous pression) étant ajoutée à la composition dans la lance afin d'assurer l'humidification de la composition juste au moment de la projection. Dry spraying is a technique in which a pulverulent composition is propelled, in particular by compressed air, along a pipe towards a spray lance, water (generally under pressure) being added to the composition. in the lance in order to ensure the humidification of the composition just at the moment of projection.
Cette technique est aujourd'hui utilisée en travaux neufs ou (surtout) en réparation d'ouvrages anciens pour projeter des couches de béton sur un support revêtu d'armatures. Elle est essentiellement utilisée pour réaliser des formes très complexes ou pour des chantiers difficiles d'accès (tunnels, travaux souterrains...). This technique is used today in new work or (especially) in repairing old structures to project layers of concrete onto a support coated with reinforcements. It is mainly used to produce very complex shapes or for sites that are difficult to access (tunnels, underground works, etc.).
Les inventeurs ont pu mettre en évidence qu'une telle technique pouvait être employée pour réaliser des murs présentant une bonne résistance mécanique et une bonne durabilité, à partir d'une composition pulvérulente comprenant de la terre crue et un liant à base de laitier. The inventors have been able to demonstrate that such a technique could be used to produce walls exhibiting good mechanical strength and good durability, from a pulverulent composition comprising raw earth and a binder based on slag.
L'utilisation de terre crue permet à la fois de réduire les émissions de gaz à effet de serre et la déplétion de ressources abiotiques. La terre crue est de préférence issue de l'excavation de sols situés sur le chantier ou à proximité du chantier, de sorte qu'elle ne nécessite pas ou peu de transport. On peut notamment utiliser, pour réaliser les murs d'un bâtiment, la terre excavée en vue de la réalisation des fondations dudit bâtiment. Alternativement, la terre crue peut provenir de chantiers voisins, par exemple de chantiers de travaux publics (réalisation de tunnels pour moyens de transport souterrains etc...). Le procédé permet donc de recycler ces terres excavées (réduisant ainsi les déchets générés par le chantier) et de réduire le besoin en béton ou en matériaux préfabriqués ainsi que leur transport. The use of raw land makes it possible both to reduce greenhouse gas emissions and the depletion of abiotic resources. The raw earth is preferably obtained from the excavation of soils located on the site or near the site, so that it requires little or no transport. In particular, it is possible to use, to make the walls of a building, the earth excavated with a view to making foundations of said building. Alternatively, the raw earth can come from neighboring sites, for example from public works sites (construction of tunnels for underground means of transport, etc.). The process therefore makes it possible to recycle this excavated soil (thus reducing the waste generated by the site) and to reduce the need for concrete or prefabricated materials as well as their transport.
L'utilisation de laitier, par rapport au ciment Portland ou aux matériaux pouzzolaniques, permet de réduire les variations dimensionnelles d'origine thermique, et donc le risque d'apparition de fissures. Cette propriété pourrait être due au fait que la chaleur dégagée lors de la réaction d'hydratation est plus faible. La résistance mécanique à long terme et la durabilité du matériau constituant la paroi sont également meilleures dans le cas de l'utilisation de laitier, probablement car sa microstructure est moins perméable aux agents agressifs. The use of slag, compared to Portland cement or pozzolanic materials, makes it possible to reduce dimensional variations of thermal origin, and therefore the risk of the appearance of cracks. This property could be due to the fact that the heat released during the hydration reaction is lower. The long-term mechanical strength and durability of the material constituting the wall are also better in the case of the use of slag, probably because its microstructure is less permeable to aggressive agents.
La paroi peut être un mur extérieur ou intérieur d'un bâtiment. Les pièces d'ossature ont de préférence une fonction porteuse. Il s'agit par exemple de poteaux et de poutres, notamment en béton (généralement armé), en bois ou en métal (notamment en acier). Les pièces d'ossature sont assemblées de manière à créer l'ossature porteuse du bâtiment, assurant sa rigidité et sa stabilité. The wall can be an exterior or interior wall of a building. The framework parts preferably have a supporting function. These are, for example, posts and beams, in particular in concrete (generally reinforced), in wood or in metal (in particular in steel). The frame pieces are assembled in such a way as to create the load-bearing frame of the building, ensuring its rigidity and stability.
Lors de la projection par voie sèche, la composition pulvérulente est de préférence propulsée par de l'air comprimé vers une lance de projection. La composition est sèche au sens où elle n'est pas mélangée à de l'eau de gâchage pour former une pâte. Certains constituants de la composition, notamment la terre, peuvent toutefois être légèrement humides. Le pourcentage d'humidité de la composition pulvérulente ne dépasse généralement pas 15%, notamment 10% et même 5% en poids. L'eau est ajoutée à la composition dans la lance ou à proximité de la lance, afin d'assurer l'humidification de la composition juste au moment de la projection ou juste avant celle-ci. During dry spraying, the pulverulent composition is preferably propelled by compressed air towards a spray lance. The composition is dry in the sense that it is not mixed with the mixing water to form a paste. Some constituents of the composition, especially soil, may however be slightly wet. The percentage of humidity of the pulverulent composition generally does not exceed 15%, in particular 10% and even 5% by weight. Water is added to the composition in the lance or near the lance, so to ensure the humidification of the composition just at the time of projection or just before it.
Lors de la projection, au moins un élément de maintien est de préférence disposé entre les pièces d'ossature de manière à retenir la composition projetée. During spraying, at least one retaining element is preferably placed between the frame pieces so as to retain the projected composition.
Cet élément de maintien est de préférence sous forme d'un panneau ou d'une plaque, notamment à base de bois (par exemple du type panneau OSB), de métal ou de plâtre (par exemple du type plaque de plâtre), ou encore sous forme de tissu ou de treillis à mailles serrées. This retaining element is preferably in the form of a panel or a plate, in particular based on wood (for example of the OSB panel type), of metal or of plaster (for example of the plasterboard type), or else in the form of a close-knit fabric or mesh.
Selon un mode de réalisation, l'élément de maintien est démonté à l'issue de la réalisation de la paroi. According to one embodiment, the retaining element is removed after completion of the wall.
Selon un autre mode de réalisation, l'élément de maintien reste en place pour former une partie de la paroi du bâtiment. La paroi selon l'invention comprend donc dans ce cas l'élément de maintien. Lorsque l'élément de maintien est une plaque de plâtre, cette option est préférée. According to another embodiment, the retaining element remains in place to form part of the wall of the building. The wall according to the invention therefore comprises in this case the retaining element. When the holding element is plasterboard, this option is preferred.
L'épaisseur du mur obtenu est de préférence comprise entre 10 et 30 cm, notamment entre 12 et 25 cm, par exemple voisine de 15 cm. Il s'agit donc bien d'un mur (autoportant) et non d'un enduit déposé sur un mur préexistant. The thickness of the wall obtained is preferably between 10 and 30 cm, in particular between 12 and 25 cm, for example close to 15 cm. It is therefore indeed a wall (self-supporting) and not a coating deposited on a pre-existing wall.
Le procédé selon l'invention utilise une composition pulvérulente comprenant de la terre crue et un liant à base de laitier. Les détails qui suivent concernent cette composition pulvérulente. The process according to the invention uses a pulverulent composition comprising raw earth and a binder based on slag. The following details relate to this powdery composition.
Dans l'ensemble du présent texte, toutes les teneurs et proportions sont exprimées en poids. Throughout this text, all the contents and proportions are expressed by weight.
La teneur en liant dans la composition est comprise entre 1 et 40%, notamment entre 2 et 30%, voire entre 4 et 20% ou encore entre 5 et 15%, par rapport au poids de composition pulvérulente. On entend par liant un liant unique ou un mélange de liants. Dans ce dernier cas, le terme « liant » recouvre collectivement ce mélange, et les proportions indiquées par rapport au liant prennent en compte le poids total de liant. The binder content in the composition is between 1 and 40%, in particular between 2 and 30%, or even between 4 and 20% or alternatively between 5 and 15%, relative to the weight of pulverulent composition. By binder is meant a single binder or a mixture of binders. In the latter case, the term “binder” collectively covers this mixture, and the proportions indicated with respect to the binder take into account the total weight of binder.
Le liant sert, dans la paroi finale, à lier les granulats de manière à former un matériau rigide présentant une résistance mécanique suffisante. The binder serves, in the final wall, to bind the aggregates so as to form a rigid material having sufficient mechanical strength.
Le liant de la composition pulvérulente comprend un laitier. La proportion pondérale de laitier par rapport au poids total de liant est d'au moins 30%, notamment d'au moins 40%, voire d'au moins 50% ou d'au moins 60% ou encore d'au moins 70%. Cette proportion peut être de 100%, au sens où le liant consiste en un (ou plusieurs) laitier(s), ou d'au plus 95% ou d'au plus 90%. The binder of the powder composition comprises a slag. The proportion by weight of slag relative to the total weight of binder is at least 30%, in particular at least 40%, or even at least 50% or at least 60% or even at least 70% . This proportion may be 100%, in the sense that the binder consists of one (or more) slag (s), or at most 95% or at most 90%.
Un laitier est un sous-produit d'un procédé industriel mettant en œuvre la fusion d'une matière de départ, fusion destinée à séparer des métaux d'une phase d'oxydes, cette dernière étant appelée « laitier ». L'utilisation de laitier permet de réduire l'empreinte carbone de la composition, et donc du procédé, en comparaison avec l'utilisation d'un ciment. A slag is a by-product of an industrial process involving the fusion of a starting material, fusion intended to separate metals from an oxide phase, the latter being called “slag”. The use of slag makes it possible to reduce the carbon footprint of the composition, and therefore of the process, in comparison with the use of a cement.
Le laitier est de préférence granulé, au sens où il a subi une trempe thermique à l'eau ayant pour conséquence l'obtention de grains en général majoritairement amorphes. Le laitier granulé est ensuite de préférence broyé afin de le rendre plus actif. Le laitier est donc de préférence un laitier granulé broyé. The slag is preferably granulated, in the sense that it has undergone thermal quenching with water, the consequence of which is to obtain grains which are generally predominantly amorphous. The granulated slag is then preferably ground in order to make it more active. The slag is therefore preferably a ground granulated slag.
De préférence le laitier est un laitier de haut fourneau granulé broyé. Un tel laitier, utilisé en tant que liant, présente l'avantage d'être insensible à l'attaque sulfatique externe, ce qui est avantageux notamment si la terre crue contient des sulfates de calcium. Le laitier (notamment le laitier de haut-fourneau granulé broyé) est de préférence activé. Preferably the slag is a ground granulated blast furnace slag. Such a slag, used as a binder, has the advantage of being insensitive to external sulphate attack, which is advantageous in particular if the raw earth contains calcium sulphates. The slag (in particular ground granulated blast furnace slag) is preferably activated.
Le liant comprend alors, en plus du laitier, un activateur. On entend ici par activateur un composé activateur (qui améliore la prise et/ou le durcissement du laitier) ou, collectivement, un mélange de tels composés. La proportion totale d'activateur dans le liant est de préférence comprise entre 1 et 20%, notamment entre 2 et 15% en poids. The binder then comprises, in addition to the slag, an activator. By activator is meant here an activating compound (which improves the setting and / or hardening of the slag) or, collectively, a mixture of such compounds. The total proportion of activator in the binder is preferably between 1 and 20%, in particular between 2 and 15% by weight.
L'activateur est de préférence choisi dans le groupe formé par : les bases (notamment les hydroxydes de métaux alcalins, les silicates de métaux alcalins et les carbonates de métaux alcalins) ; les microparticules de laitier d'une finesse supérieure ou égale à 6000 Blaine ; les microparticules de carbonate de calcium et/ou de magnésium, d'hydrates de silicate de calcium ou d'hydrates de silicate d'aluminium ; les laitiers alumineux granulés broyés ; les sources de sulfate de calcium (notamment le gypse, l'hémihydrate ou l'anhydrite) ; les sulfates, halogénures, nitrates ou carboxylates, de métaux alcalins ; le ciment Portland ; la chaux ; et les mélanges de deux ou plus de ces composés. The activator is preferably chosen from the group formed by: bases (in particular alkali metal hydroxides, alkali metal silicates and alkali metal carbonates); microparticles of slag with a fineness greater than or equal to 6000 Blaine; microparticles of calcium and / or magnesium carbonate, calcium silicate hydrates or aluminum silicate hydrates; ground aluminous granulated slags; sources of calcium sulphate (especially gypsum, hemihydrate or anhydrite); alkali metal sulfates, halides, nitrates or carboxylates; Portland cement; lime; and mixtures of two or more of these compounds.
Selon un mode de réalisation préféré, l'activateur comprend des microparticules de laitier d'une finesse supérieure ou égale à 6000 Blaine, notamment comprise entre 6000 et 15000 Blaine, en une teneur comprise entre 1 et 35%, notamment entre 5 et 15%, du poids de liant. L'activateur peut en outre comprendre au moins un des composés suivants : une base, notamment choisie parmi les hydroxydes, carbonates et silicates, de métaux alcalins et/ou alcalino-terreux, en une teneur totale d'au plus 1%, notamment comprise entre 0,2 et 0,4%, par rapport au poids de liant ; une source de sulfate de calcium ; des sulfates de métaux alcalins, en une teneur totale d'au plus 1%, notamment comprise entre 0,2 et 0,4%, par rapport au poids de liant ; du ciment Portland, un ciment alumineux ou un ciment suifoalumineux, en une teneur totale d'au plus 4% par rapport au poids de liant. According to a preferred embodiment, the activator comprises slag microparticles with a fineness greater than or equal to 6000 Blaine, in particular between 6000 and 15000 Blaine, in a content of between 1 and 35%, in particular between 5 and 15% , weight of binder. The activator can also comprise at least one of the following compounds: a base, in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 1%, in particular comprised between 0.2 and 0.4%, relative to the weight of binder; a source of calcium sulfate; alkali metal sulphates, in a total content of at most 1%, in particular between 0.2 and 0.4%, based on the weight of binder; Portland cement, an aluminous cement or a sulphoaluminous cement, in a total content of not more than 4% relative to the weight of binder.
Selon un autre mode de réalisation préféré, l'activateur comprend des microparticules de carbonate de calcium et/ou de magnésium, d'hydrates de silicate de calcium ou d'hydrates de silicate d'aluminium, dont la surface spécifique BET (azote) est supérieure à 1 m2/g et le diamètre moyen est inférieur à 5 pm. L'activateur peut en outre comprendre au moins un des composés suivants : une base, notamment choisie parmi les hydroxydes, carbonates et silicates, de métaux alcalins et/ou alcalino-terreux, en une teneur totale d'au plus 1%, notamment comprise entre 0,2 et 0,4%, par rapport au poids de liant ; une source de sulfate de calcium ; des sulfates de métaux alcalins, en une teneur totale d'au plus 1%, notamment comprise entre 0,2 et 0,4%, par rapport au poids de liant ; du nitrate de calcium, du formiate de calcium, du ciment Portland, un ciment alumineux ou un ciment sulfoalumineux, en une teneur totale d'au plus 5% par rapport au poids de liant. According to another preferred embodiment, the activator comprises microparticles of calcium and / or magnesium carbonate, calcium silicate hydrates or aluminum silicate hydrates, the BET (nitrogen) specific surface of which is greater than 1 m 2 / g and the average diameter is less than 5 µm. The activator can also comprise at least one of the following compounds: a base, in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 1%, in particular comprised between 0.2 and 0.4%, relative to the weight of binder; a source of calcium sulfate; alkali metal sulphates, in a total content of at most 1%, in particular between 0.2 and 0.4%, relative to the weight of binder; calcium nitrate, calcium formate, Portland cement, an aluminous cement or a sulphoaluminous cement, in a total content of not more than 5% relative to the weight of binder.
Selon encore un autre mode de réalisation préféré, l'activateur comprend un laitier alumineux granulé broyé, notamment dont la composition chimique comprend 30 à 60% en poids d'alumine, 5 à 25% en poids de silice et 20 à 40% en chaux, l'alumine étant le constituant le plus abondant. Le laitier alumineux granulé broyé est de préférence issu du recyclage par fusion totale de catalyseurs utilisés pour la désulfuration des produits pétroliers, notamment de catalyseurs à base de molybdène et/ou de cobalt. L'activateur peut en outre comprendre au moins un des composés suivants : une base, notamment choisie parmi les hydroxydes, carbonates et silicates, de métaux alcalins et/ou alcalino-terreux, en une teneur totale d'au plus 2% par rapport au poids de liant ; une source de sulfate de calcium ; des sulfates de métaux alcalins, en une teneur totale d'au plus 2% par rapport au poids de liant ; du ciment Portland, un ciment alumineux ou un ciment sulfoalumineux, en une teneur totale d'au plus 2% par rapport au poids de liant. According to yet another preferred embodiment, the activator comprises a ground granulated aluminous slag, in particular the chemical composition of which comprises 30 to 60% by weight of alumina, 5 to 25% by weight of silica and 20 to 40% of lime. , alumina being the most abundant constituent. The ground granulated aluminous slag is preferably obtained from the recycling by total melting of catalysts used for the desulphurization of petroleum products, in particular of catalysts based on molybdenum and / or cobalt. The activator can also comprise at least one of the following compounds: a base, in particular chosen from hydroxides, carbonates and silicates, of alkali metals and / or alkaline earth, in a total content of at most 2% relative to the weight of binder; a source of calcium sulfate; sulphates alkali metals, in a total content of at most 2% relative to the weight of binder; Portland cement, an aluminous cement or a sulphoaluminous cement, in a total content of not more than 2% relative to the weight of binder.
Un laitier est un liant hydraulique latent, c'est-à- dire un liant dont le caractère hydraulique peut être obtenu grâce à l'ajout d'au moins un activateur. On entend par liant hydraulique un liant qui fait prise et durcit sous l'eau. Dans ce dernier cas, l'activateur fait partie du liant et la teneur totale en activateur est comprise dans la teneur totale en liant. A slag is a latent hydraulic binder, that is to say a binder whose hydraulic character can be obtained by adding at least one activator. By hydraulic binder is meant a binder which sets and hardens under water. In the latter case, the activator is part of the binder and the total activator content is included in the total binder content.
Le liant peut en outre comprendre d'autres liants hydrauliques, en plus du laitier. The binder can further include other hydraulic binders, in addition to slag.
Le ou chaque liant hydraulique (additionnel) est de préférence choisi dans le groupe formé par les ciments Portland, les ciments bélitiques, les ciments alumineux, les ciments sulfoalumineux, les ciments de mélanges pouzzolaniques, les cendres volantes, les métakaolins, la chaux hydraulique et les mélanges de deux ou plus de ces liants hydrauliques. Les cendres volantes et les métakaolins sont des liants pouzzolaniques qui nécessitent une activation par une source de chaux. Dans ce cas la source de chaux fait partie du liant. The or each (additional) hydraulic binder is preferably chosen from the group formed by Portland cements, belitic cements, aluminous cements, sulphoaluminous cements, pozzolanic mixture cements, fly ash, metakaolins, hydraulic lime and mixtures of two or more of these hydraulic binders. Fly ash and metakaolins are pozzolanic binders which require activation by a lime source. In this case the lime source is part of the binder.
Afin de réduire l'empreinte carbone de la composition pulvérulente, la proportion pondérale totale en ciment Portland, ciment alumineux, ciment sulfoalumineux, chaux hydraulique et chaux aérienne par rapport au poids total de liant est de préférence d'au plus 20%, notamment d'au plus 10% et même d'au plus 5%. Cette proportion est même avantageusement nulle. In order to reduce the carbon footprint of the pulverulent composition, the total proportion by weight of Portland cement, aluminous cement, sulphoaluminous cement, hydraulic lime and aerial lime relative to the total weight of binder is preferably at most 20%, in particular d 'at most 10% and even at most 5%. This proportion is even advantageously zero.
La teneur en granulats dans la composition est comprise entre 60 et 99%, notamment entre 70 et 98%, voire entre 80 et 96%, ou encore entre 85 et 95%, par rapport au poids de composition pulvérulente. The aggregate content in the composition is between 60 and 99%, in particular between 70 and 98%, or even between 80 and 96%, or alternatively between 85 and 95%, relative to the weight of pulverulent composition.
Les granulats comprennent de la terre crue. La terre crue contient typiquement des sables, des argiles et du limon, en des teneurs variables selon le lieu où elle est excavée. Rappelons que de manière préférée, le lieu d'excavation est situé sur le lieu de construction ou à proximité pour ne pas impacter négativement l'empreinte environnementale du procédé et réduire la quantité de déchets générés par le chantier. Aggregates include raw earth. Raw earth typically contains sands, clays and silt, in varying amounts depending on where it is excavated. Remember that preferably, the excavation site is located on the construction site or nearby so as not to negatively impact the environmental footprint of the process and reduce the amount of waste generated by the site.
La proportion pondérale de terre crue par rapport au poids total de granulats est d'au moins 50%, notamment d'au moins 60% et même d'au moins 70% ou d'au moins 80%. Elle peut même être de 100%, c'est-à-dire que les granulats consistent en de la terre crue. The proportion by weight of raw earth relative to the total weight of aggregates is at least 50%, in particular at least 60% and even at least 70% or at least 80%. It can even be 100%, i.e. the aggregates consist of raw earth.
La terre crue peut en outre avoir subi des opérations de préparation à la mise en œuvre du procédé, notamment mais pas uniquement une opération de criblage. Lorsque des opérations de préparation sont réalisées, elles le sont de préférence sur le lieu d'excavation, ce dernier étant de préférence le lieu de construction. Le procédé selon l'invention peut donc comprendre une étape de criblage de la terre crue préalablement à l'étape de projection. Une étape de séchage peut également être pratiquée si besoin. The raw earth may also have undergone preparatory operations for the implementation of the method, in particular but not only a screening operation. When preparation operations are carried out, they are preferably carried out at the site of excavation, the latter preferably being the site of construction. The method according to the invention can therefore comprise a step of screening the raw earth prior to the projection step. A drying step can also be carried out if necessary.
Les granulats peuvent en outre comprendre d'autres granulats que la terre crue, et en particulier des granulats légers et/ou des fibres. The aggregates can also comprise aggregates other than raw earth, and in particular lightweight aggregates and / or fibers.
Les granulats légers permettent de diminuer la densité du matériau constituant le mur, donc son poids, permettant de ce fait de réduire le poids, et donc l'empreinte environnementale, des pièces d'ossature du bâtiment. La présence de granulats légers permet en outre de réduire le module d'élasticité ainsi que la conductivité thermique du matériau final. Les granulats légers ont de préférence une masse volumique apparente d'au plus 900 kg/m3, de préférence comprise entre 50 kg/m3 et 900 kg/m3, et en particulier entre 150 kg/m3 et 800 kg/m3. La masse volumique apparente des granulats légers peut notamment être mesurée selon la norme EN 1097-3 :1998. Lightweight aggregates make it possible to reduce the density of the material constituting the wall, and therefore its weight, thereby making it possible to reduce the weight, and therefore the environmental footprint, of the structural parts of the building. The presence of light aggregates also makes it possible to reduce the modulus of elasticity as well as the thermal conductivity of the final material. The light aggregates preferably have a bulk density of at most 900 kg / m 3 , preferably between 50 kg / m 3 and 900 kg / m 3 , and in particular between 150 kg / m 3 and 800 kg / m 3 . The bulk density of light aggregates can in particular be measured according to standard EN 1097-3: 1998.
Les granulats légers sont de préférence choisis parmi la pouzzolane, la perlite, la vermiculite, les billes de verre expansé, les microsphères creuses de verre, les cénosphères, les silicates expansés, les argiles expansées, les billes de polystyrène expansé, le liège et leurs mélanges. De préférence, les granulats légers sont d'origine naturelle, par exemples des pouzzolanes. La proportion pondérale de granulats légers par rapport au poids total de granulats est de préférence d'au plus 50%, notamment d'au plus 40%, par exemple comprise entre 1 et 50%, notamment entre 5 et 35%. The light aggregates are preferably chosen from pozzolan, perlite, vermiculite, expanded glass beads, hollow glass microspheres, cenospheres, expanded silicates, expanded clays, expanded polystyrene beads, cork and theirs. mixtures. Preferably, the light aggregates are of natural origin, for example pozzolans. The proportion by weight of light aggregates relative to the total weight of aggregates is preferably at most 50%, in particular at most 40%, for example between 1 and 50%, in particular between 5 and 35%.
Les fibres sont de préférence des fibres naturelles (végétales ou animales), notamment des fibres végétales, telles que des fibres de chanvre, de lin ou de bois. Les fibres permettent de renforcer mécaniquement le matériau. La proportion pondérale de fibres par rapport au poids total de granulats est de préférence d'au plus 10%, notamment d'au plus 5%, par exemple comprise entre 1 et 10%, notamment entre 2 et 8%. The fibers are preferably natural fibers (plant or animal), in particular plant fibers, such as hemp, flax or wood fibers. The fibers allow the material to be mechanically reinforced. The proportion by weight of fibers relative to the total weight of aggregates is preferably at most 10%, in particular at most 5%, for example between 1 and 10%, especially between 2 and 8%.
La composition pulvérulente peut en outre, comprendre, en plus du liant et des granulats, divers additifs ou adjuvants, choisis notamment parmi les agents rhéologiques, les agents rétenteurs d'eau, les agents entraîneurs d'air, les agents épaississants, les agents de protection biocides, les agents dispersants, les pigments, les accélérateurs et/ou les retardateurs, les résines polymériques. La teneur totale en additifs et adjuvants varie de préférence entre 0,001 et 5% en poids par rapport au poids total de la composition. The pulverulent composition may also comprise, in addition to the binder and aggregates, various additives or adjuvants, chosen in particular from rheological agents, water-retaining agents, air-entraining agents, thickening agents, protection biocides, dispersing agents, pigments, accelerators and / or retarders, polymeric resins. The total content of additives and adjuvants preferably varies between 0.001 and 5% by weight relative to the total weight of the composition.
Les différentes caractéristiques préférées détaillées ci-avant concernant le liant et les granulats peuvent être combinées selon toutes les combinaisons techniquement possibles, sans que toutes ces combinaisons soient ici indiquées, dans un souci de concision. The various preferred characteristics detailed above concerning the binder and the aggregates can be combined according to all the technically possible combinations, without all these combinations being indicated here, for the sake of brevity.
A titre d'exemple d'une combinaison préférée, la composition pulvérulente peut comprendre entre 4 et 20% d'un liant et entre 80 et 96% de granulats, la proportion de laitier de haut-fourneau granulé broyé par rapport au poids de liant étant comprise entre 70 et 100% et la proportion de terre crue par rapport au poids de granulats étant comprise entre 60 et 100%. As an example of a preferred combination, the pulverulent composition can comprise between 4 and 20% of a binder and between 80 and 96% of aggregates, the proportion of ground granulated blast furnace slag relative to the weight of binder being between 70 and 100% and the proportion of raw earth relative to the weight of aggregates being between 60 and 100%.
Lorsque la composition doit être mise en œuvre par projection par voie sèche, le diamètre maximal (Dmax), déterminé par tamisage, est de préférence d'au plus 20 mm, notamment d'au plus 16 mm. De préférence, la composition n'est toutefois pas trop fine, de manière à ce que les granulats plus grossiers compactent les particules fines de la composition et favorisent ainsi l'adhérence de la matière sur l'élément de maintien. De préférence, la distribution granulométrique de la composition est telle que la proportion de particules ayant une taille comprise entre 8 et 16 mm, notamment entre 10 et 16 mm, est d'au moins 10% en poids, de préférence entre 10% et 30% en poids. La distribution granulométrique est déterminée par tamisage. When the composition is to be used by dry spraying, the maximum diameter (Dmax), determined by sieving, is preferably at most 20 mm, in particular at most 16 mm. Preferably, however, the composition is not too fine, so that the coarser aggregates compact the fine particles of the composition and thus promote the adhesion of the material to the holding member. Preferably, the particle size distribution of the composition is such that the proportion of particles having a size between 8 and 16 mm, in particular between 10 and 16 mm, is at least 10% by weight, preferably between 10% and 30 % in weight. The particle size distribution is determined by sieving.
Les exemples de réalisation qui suivent illustrent l'invention de manière non-limitative. The exemplary embodiments which follow illustrate the invention in a non-limiting manner.
Le tableau ci-après indique les compositions pulvérulentes testées (en pourcentages pondéraux). The table below indicates the pulverulent compositions tested (in weight percentages).
L'exemple 1 est un exemple comparatif n'utilisant pas de laitier. Example 1 is a comparative example not using slag.
Dans les exemples selon l'invention, le laitier était un laitier de haut-fourneau granulé broyé. In the examples according to the invention, the slag was a ground granulated blast furnace slag.
Le laitier alumineux était un laitier alumineux granulé broyé, issu du recyclage par fusion totale de catalyseurs de désulfurisation des produits pétroliers à base de cobalt et de molybdène. Les constituants principaux de ce laitier sont l'alumine (41%), la chaux (32,6%), la silice (12,6%), l'oxyde de magnésium (8,9%), l'oxyde de fer (1,6%) et le soufre (1,6%). Des murs ont été obtenus par projection par voie sèche de ces compositions entre des bois d'ossatures, contre des éléments de maintien en OSB. The aluminous slag was a ground granulated aluminous slag, resulting from the recycling by total melting of catalysts for the desulphurization of petroleum products based on cobalt and molybdenum. The main constituents of this slag are alumina (41%), lime (32.6%), silica (12.6%), magnesium oxide (8.9%), iron oxide (1.6%) and sulfur (1.6%). Walls were obtained by dry spraying of these compositions between timber frames, against OSB retaining elements.
L'épaisseur des murs obtenus était de 9,5 cm, 14,5 cm et 18 cm. The thickness of the walls obtained was 9.5 cm, 14.5 cm and 18 cm.
Après projection, la matière était figée immédiatement après l'application et dure au toucher au bout de 2 à 24 heures. Le séchage, l'acquisition des propriétés mécaniques et la possibilité de recouvrement (par un enduit) dépend ensuite de divers facteurs tels que l'humidité de la composition utilisée, l'épaisseur d'application et les conditions climatiques. After spraying, the material was set immediately after application and hard to the touch after 2 to 24 hours. The drying, the acquisition of the mechanical properties and the possibility of covering (by a coating) then depend on various factors such as the humidity of the composition used, the thickness of application and the climatic conditions.
Des murs intègres, sans fissures et présentant une résistance mécanique satisfaisante ont été obtenus. L'absence de fissures s'est révélée toutefois plus facile à obtenir lorsque le liant était à base de laitier. Integral walls, without cracks and having a satisfactory mechanical resistance were obtained. The absence of cracks, however, proved to be easier to obtain when the binder was based on slag.

Claims

Revendications Claims
1. Procédé d'obtention d'une paroi, dans lequel on réalise un mur de remplissage entre des pièces d'ossature par projection par voie sèche d'une composition pulvérulente comprenant : 1. Process for obtaining a wall, in which a filling wall is produced between the framework pieces by dry spraying of a powder composition comprising:
- de 1 à 40% en poids de liant, dont du laitier, la proportion pondérale de laitier par rapport au poids total de liant étant d'au moins 30%, - from 1 to 40% by weight of binder, including slag, the proportion by weight of slag relative to the total weight of binder being at least 30%,
- de 60 à 99% en poids de granulats, dont de la terre crue, la proportion pondérale de terre crue par rapport au poids total de granulats étant d'au moins 50%. - from 60 to 99% by weight of aggregates, including raw earth, the proportion by weight of raw earth relative to the total weight of aggregates being at least 50%.
2. Procédé selon la revendication précédente, dans lequel les pièces d'ossature ont une fonction porteuse, et sont notamment des poteaux et des poutres, en béton, en bois ou en métal. 2. Method according to the preceding claim, wherein the frame parts have a load-bearing function, and are in particular posts and beams, made of concrete, wood or metal.
3. Procédé selon l'une des revendications précédentes, dans lequel, lors de la projection, au moins un élément de maintien est disposé entre les pièces d'ossature de manière à retenir la composition projetée. 3. Method according to one of the preceding claims, wherein, during spraying, at least one retaining element is arranged between the frame parts so as to retain the projected composition.
4. Procédé selon la revendication précédente, dans lequel l'élément de maintien est sous forme d'un panneau ou d'une plaque, à base de bois, de métal ou de plâtre, ou sous forme de tissu ou de treillis à mailles serrées. 4. Method according to the preceding claim, wherein the retaining element is in the form of a panel or a plate, based on wood, metal or plaster, or in the form of a close-meshed fabric or mesh. .
5. Procédé selon l'une des revendications précédentes, tel que l'épaisseur du mur obtenu est comprise entre 10 et 30 cm, notamment entre 12 et 25 cm. 5. Method according to one of the preceding claims, such that the thickness of the wall obtained is between 10 and 30 cm, in particular between 12 and 25 cm.
6. Composition pulvérulente apte à être utilisée dans le procédé selon l'une des revendications 1 à 5, comprenant :6. A pulverulent composition suitable for use in the process according to one of claims 1 to 5, comprising:
- de 1 à 40% en poids de liant, dont du laitier, la proportion pondérale de laitier par rapport au poids total de liant étant d'au moins 30%, - de 60 à 99% en poids de granulats, dont de la terre crue, la proportion pondérale de terre crue par rapport au poids total de granulats étant d'au moins 50%. - from 1 to 40% by weight of binder, including slag, the proportion by weight of slag relative to the total weight of binder being at least 30%, - from 60 to 99% by weight of aggregates, including raw earth, the proportion by weight of raw earth relative to the total weight of aggregates being at least 50%.
7. Composition selon la revendication précédente, dans laquelle la teneur en liant est comprise entre 2 et 30% et la teneur en granulats est comprise entre 70 et 98%, par rapport au poids de composition pulvérulente. 7. Composition according to the preceding claim, in which the binder content is between 2 and 30% and the aggregate content is between 70 and 98%, relative to the weight of pulverulent composition.
8. Composition selon l'une des revendications 6 ou 7, dans laquelle la proportion pondérale de terre crue par rapport au poids total de granulats est d'au moins 60%. 8. Composition according to one of claims 6 or 7, wherein the weight proportion of raw earth relative to the total weight of aggregates is at least 60%.
9. Composition selon l'une des revendications 6 à 8, dans laquelle les granulats comprennent en outre des granulats légers et/ou des fibres, notamment des fibres végétales. 9. Composition according to one of claims 6 to 8, in which the aggregates further comprise light aggregates and / or fibers, in particular plant fibers.
10. Composition selon l'une des revendications 6 à 9, dans laquelle le laitier est un laitier de haut-fourneau granulé broyé, notamment activé. 10. Composition according to one of claims 6 to 9, in which the slag is a ground granulated blast furnace slag, in particular activated.
11. Composition selon la revendication précédente, dans laquelle le liant comprend un activateur, et la proportion totale d'activateur dans le liant est comprise entre 1 et 20%, notamment entre 2 et 15% en poids. 11. Composition according to the preceding claim, in which the binder comprises an activator, and the total proportion of activator in the binder is between 1 and 20%, in particular between 2 and 15% by weight.
12. Composition selon la revendication précédente, dans laquelle l'activateur est choisi dans le groupe formé par : les bases, les microparticules de laitier d'une finesse supérieure ou égale à 6000 Blaine, les microparticules de carbonate de calcium et/ou de magnésium, d'hydrates de silicate de calcium ou d'hydrates de silicate d'aluminium, les laitiers alumineux granulés broyés, les sources de sulfate de calcium, les sulfates de métaux alcalins, les halogénures de métaux alcalins, les nitrates de métaux alcalins, les carboxylates de métaux alcalins, le ciment Portland, la chaux et les mélanges de deux ou plus de ces composés. 12. Composition according to the preceding claim, in which the activator is chosen from the group formed by: bases, microparticles of slag with a fineness greater than or equal to 6000 Blaine, microparticles of calcium carbonate and / or magnesium. , calcium silicate hydrates or aluminum silicate hydrates, ground granulated aluminous slags, sources of calcium sulphate, alkali metal sulphates, alkali metal halides, alkali metal nitrates, alkali metal carboxylates, Portland cement, lime and mixtures of two or more of these compounds.
13. Composition selon l'une des revendications 6 à 12, dans laquelle le liant comprend un liant hydraulique additionnel choisi dans le groupe formé par les ciments Portland, les ciments bélitiques, les ciments alumineux, les ciments sulfoalumineux, les ciments de mélanges pouzzolaniques, les cendres volantes, les métakaolins, la chaux hydraulique et les mélanges de deux ou plus de ces liants hydrauliques. 13. Composition according to one of claims 6 to 12, in which the binder comprises an additional hydraulic binder chosen from the group formed by Portland cements, belitic cements, aluminous cements, sulphoaluminous cements, cements of pozzolanic mixtures, fly ash, metakaolins, hydraulic lime and mixtures of two or more of these hydraulic binders.
14. Composition selon l'une des revendications 6 à 13, dans laquelle la distribution granulométrique de la composition est telle que la proportion de particules ayant une taille comprise entre 8 et 16 mm, notamment entre 10 et 16 mm, est d'au moins 10% en poids, de préférence entre 10% et 30% en poids. 14. Composition according to one of claims 6 to 13, in which the particle size distribution of the composition is such that the proportion of particles having a size between 8 and 16 mm, in particular between 10 and 16 mm, is at least. 10% by weight, preferably between 10% and 30% by weight.
15. Procédé selon l'une des revendications 1 à 5, dans lequel la composition pulvérulente est une composition selon l'une quelconque des revendications 6 à 14. 15. Method according to one of claims 1 to 5, in which the pulverulent composition is a composition according to any one of claims 6 to 14.
16. Paroi susceptible d'être obtenue par la mise en œuvre du procédé selon l'une des revendications 1 à 5 ou 15. 16. Wall capable of being obtained by implementing the method according to one of claims 1 to 5 or 15.
EP21710515.4A 2020-03-12 2021-03-12 Manufacture of a wall by dry spraying of a composition comprising unbaked earth Pending EP4118057A1 (en)

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FR2002449A FR3108115B1 (en) 2020-03-12 2020-03-12 Manufacture of a wall by dry projection of a composition comprising raw earth
PCT/EP2021/056351 WO2021180931A1 (en) 2020-03-12 2021-03-12 Manufacture of a wall by dry spraying of a composition comprising unbaked earth

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Publication number Priority date Publication date Assignee Title
FR2598349B1 (en) * 1986-05-07 1988-09-23 Gilles Pierre METHOD FOR MANUFACTURING PISA WALLS, OR STABILIZED EARTH, PROJECTING MACHINE SUITABLE FOR ITS IMPLEMENTATION, AND WALL THUS OBTAINED
IL115527A0 (en) * 1994-10-07 1996-01-19 Easton David C Method of stabilizing earth for building earthen walls and structures
DE19542676A1 (en) * 1995-11-16 1997-05-22 Helmut Sonntag Rapidly hardening mortar mixture based on loam
EP1108697A1 (en) * 1999-12-13 2001-06-20 Ziegelei Oberdiessbach AG Building material comprising loam
FR2952050B1 (en) * 2009-11-05 2012-12-14 Saint Gobain Weber France BINDERS FOR BUILDING MATERIALS
GB201012848D0 (en) * 2010-07-30 2010-09-15 Lafarge Aggregates Ltd Cement-containing compositions
GB2489981B (en) * 2011-04-14 2013-04-10 Green Binder Technologies Ltd Cementitious binders containing ground granulated blast furnace slag
FR3016376B1 (en) * 2014-01-16 2016-03-04 Cematerre NEW IMPROVEMENT TO A PROCESS FOR MANUFACTURING AT LEAST ONE VERTICAL EARTH WALL

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FR3108115B1 (en) 2023-06-30
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CN115210194A (en) 2022-10-18

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