Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
  • C04B28/04—Portland cements
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B1/00—Producing shaped prefabricated articles from the material
  • B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
  • B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing layered articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
  • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
  • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/04—Silica-rich materials; Silicates
  • C04B14/06—Quartz; Sand
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/04—Silica-rich materials; Silicates
  • C04B14/06—Quartz; Sand
  • C04B14/062—Microsilica, e.g. colloïdal silica
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/04—Silica-rich materials; Silicates
  • C04B14/10—Clay
  • C04B14/106—Kaolin
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/26—Carbonates
  • C04B14/28—Carbonates of calcium
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/30—Oxides other than silica
  • C04B14/304—Magnesia
• • 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
  • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B18/04—Waste materials; Refuse
  • C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
  • C04B18/08—Flue dust, i.e. fly ash
• • 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
  • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B18/04—Waste materials; Refuse
  • C04B18/14—Waste materials; Refuse from metallurgical processes
  • C04B18/141—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
  • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B18/04—Waste materials; Refuse
  • C04B18/14—Waste materials; Refuse from metallurgical processes
  • C04B18/146—Silica fume
• • 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
  • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
  • C04B20/0076—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials characterised by the grain distribution
  • C04B20/008—Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder
• • 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
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/2641—Polyacrylates; Polymethacrylates
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/54—Yield strength; Tensile strength
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/732—Dimensional properties
  • B32B2307/737—Dimensions, e.g. volume or area
  • B32B2307/7375—Linear, e.g. length, distance or width
  • B32B2307/7376—Thickness
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2607/00—Walls, panels
• • 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
  • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
  • C04B2103/0068—Ingredients with a function or property not provided for elsewhere in C04B2103/00
  • C04B2103/0088—Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes
• • 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
  • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
  • C04B2103/30—Water reducers, plasticisers, air-entrainers, flow improvers
  • C04B2103/32—Superplasticisers
• • 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
  • C04B2111/00051—Mortar or concrete mixtures with an unusual low cement content, e.g. for foundations
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
  • C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
• • 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 hydraulically bound multi-layer board with at least one facing layer and at least one core layer, and a multi-layer board produced using the method.
• Multi-layer panels of the type mentioned at the outset are known in principle and are used, for example, as floor coverings, including for outdoor applications such as gardens and terraces.
• the finished products should have very good weather resistance (weathering according to DIN EN 1338/DIN EN 1339 ⁇ 50 g/m 2 ) and/or adequate abrasion resistance (abrasion according to DIN EN 1338/1339 ⁇ 20 mm).
• the board must be optimized in terms of porosity and capillarity in such a way that it has a high resistance to contamination (no capillary suction and/or very low water absorption ⁇ 1.0% according to DIN EN 1338/1339).
• Floor tiles that meet the above minimum requirements can be manufactured using different production techniques. These include the casting process, wet pressing process, vibratory pressing process, hammer mill process and the hermetic process.
• the hermetic process is mostly used for the production of two-layer terrace and pavement slabs, as well as large-format slabs for public spaces and buildings in high quality and density. Thin single-layer panels for interior use and building cladding can also be manufactured using the hermetic process.
• the visible layer facing upwards or outwards is referred to as the facing layer
• the non-visible layer facing downwards or inwards is referred to as the core or backfill layer.
• Both the facing layer and the core layer must meet the requirements of the manufacturing process.
• the facing layer is first made flowable so that after filling it fills the corners of the formwork and can even begin to level out. Leveling can be supported by vibrating or pressing on attachment distribution plates.
• the core layer on the other hand, is usually produced dry to earth-moist and is usually applied to the facing layer with a layer thickness that is as homogeneous as possible using a filling funnel and a slider.
• the production process results in a stable multi-layer panel that can be stripped immediately and that can be removed using vacuum lifting devices and stored on pallets.
• Products manufactured using the hermetic process are characterized by a special surface quality that is well suited for further processing by means of grinding, brushing and blasting.
• the hermetic process can be used to produce a stable and storable product that can be stripped immediately.
• floor panels from a thickness of 30 mm up to an edge length of 400 mm and from a thickness of 40 mm with an edge length of up to 800 mm can be manufactured using the hermetic process.
• large-format, thin multi-layer panels which have a larger edge length/thickness ratio cannot be produced, or cannot be produced satisfactorily, with previous production techniques.
• the mechanical properties and thus the usability of such large-format, thin multi-layer panels are often unsatisfactory.
• a method for producing a hydraulically bound multi-layer board with at least one facing layer and at least one core layer comprising the following steps: a. Introduction of a free-flowing facing mixture into a mold, the facing mixture containing at least the following components: i. containing at least
• directly strippable is understood in particular to mean that the multi-layer board can be removed from the mold immediately or shortly after pressing, for example by means of vacuum lifting, and/or has a strength that enables further processing and storage without formwork.
• a multilayer board can be produced which can have an edge length/thickness ratio of more than 20 and is nevertheless distinguished by a high characteristic flexural strength and/or a high characteristic breaking load.
• the advantages of the manufacturing process according to the invention are particularly evident in the case of large-format products.
• multi-layer panels produced by the method according to the invention have a high load-bearing capacity and serviceability despite the higher edge length-to-thickness ratio and are outstandingly suitable for use as floor coverings, especially for outdoor applications.
• core mixture layer layers with different water contents can form in the core mixture layer, which would lead to uneven or incomplete activation of the hydraulic binder in the core mixture layer and to a deterioration in the mechanical properties of the multilayer board.
• core mixtures that have a high fines content and low water content can lead to problems in the mixing process, such as insufficient dispersion of the fines, clumping and dust formation.
• an insufficiently mixed core concrete can be problematic with regard to the compactibility as well as the subsequent hardened concrete properties.
• the present invention now provides a manufacturing process in which the face and core mix layers optimally cooperate to produce a multilayer board with an optimized packing density and water requirement.
• the interaction of the very fine material contained in the core size with the additive contained in the core size appears to be essential for the process according to the invention.
• Fines with a mean diameter d50 smaller than the mean diameter d50 of the hydraulic binder fill the interstices of the binder particles instead of void water.
• Very fine materials with an average diameter d50 similar to a binder do not fill the gaps, but still have a lower water requirement than the binder.
• the proportion of fines in the core glue mixture does not impair sufficient pressing of the excess water from the face mix layer into the core mix layer.
• the core mixture used in the process according to the invention has an optimum water/powder ratio, which enables excellent processability of the core mixture and strength and durability of the multilayer boards.
• the core mixture contains at least the following components: i. containing glue at least
• the core mixture When introduced into the mould, the core mixture has a dry to earth-moist consistency.
• the core mixture When introduced into the mold, the core mixture preferably has a consistency of at most consistency class Fl according to DIN 1045-2 and/or EN 206.
• consistency class Fl has a slump of ⁇ 340 mm and a stiff consistency, whereas the higher consistency classes F2 to F6 have larger slumps and softer or more flowable consistencies.
• a preferred embodiment of the invention provides that the core mixture layer before pressing according to step c. a consistency of maximum consistency class Fl according to DIN 1045-2 and/or EN 206.
• the core mix layer is formed by placing a dry to semi-dry core mix in a mold, the core mix containing at least core glue and aggregate.
• the core mix contains the Core mixture, based on the total dry weight of the core mixture, at least 450 kg/m 3 , in particular 450 to 1250 kg/m 3 , more preferably 600 to 1250 kg/m 3 core glue.
• the core glue contains very fine material.
• Very fine material within the meaning of the invention is material which has an average diameter d50, determined according to ISO 13320:2009, of up to 100.0 ⁇ m. “Mean diameter” within the meaning of this invention is always to be understood as meaning the mean diameter d50 determined according to ISO 13320:2009.
• the core glue can contain very fine material with an average diameter of 1.0 to 100.0 ⁇ m.
• the core size contains fines with an average diameter d50 determined according to ISO 13320:2009 of 1.0 to 100.0 ⁇ m in an amount of 5 to 45% by volume, based on the total volume of hydraulic binder contained in the core size and fines.
• the core glue contains very fine material which has an average diameter d50, determined according to ISO 13320:2009, which is smaller than the average diameter d50, determined according to ISO 13320:2009, of the hydraulic binder contained in the core glue .
• This ultra-fine material fills the interstices of the hydraulic binder particles instead of what is known as cavity water, which means that a higher packing density and reduced water requirements can be achieved.
• such a fine material can replace part of the hydraulic binder, which in the case of a cement replacement can lead to a reduced clinker content with a lower efflorescence potential.
• the core size contains fines with a mean diameter that is smaller than the mean diameter of the hydraulic binder in an amount of 5 to 45% by volume based on the total volume of hydraulic binder and fines contained in the core size .
• the core glue contains fines with a mean diameter that is smaller than the mean diameter of the hydraulic binder in an amount of 5 to 45% by volume based on the total volume of the hydraulic binder and the fines of the core size.
• the very fine material contained in the core glue particularly preferably has an average diameter d50, determined according to ISO 13320:2009, of from 1.0 to 30.0 ⁇ m, preferably from 1.0 to 5.0 ⁇ m.
• the core glue contains very fine material with an average diameter d50, determined according to ISO 13320:2009, of 1.0 to 30.0 ⁇ m in an amount of 5 to 45% by volume, based on the total volume contained in the core glue hydraulic binder and fines.
• the core glue particularly preferably contains very fine material with an average diameter d50, determined according to ISO 13320:2009, from 1.0 to 5.0 ⁇ m in an amount from 5 to 20% by volume, in particular from 8 to 15% by volume. related to the total volume of hydraulic binder and fines contained in the core glue.
• the core glue contains ultrafine material with an average diameter d50, determined according to ISO 13320:2009, of 30.1 to 100.0 ⁇ m in an amount of 0 to 45% by volume, in particular from 0 to 25 % by volume, based on the total volume of hydraulic binder and fines contained in the core size.
• the core glue has fines with an average diameter of 30.1 to 100.0 ⁇ m in an amount of 0% by volume.
• the very fine material can be a rock aggregate, in particular a rock aggregate based on quartz and/or limestone.
• the ultra-fine material contains at least one inert powdered rock, preferably an inert powdered rock selected from the group consisting of limestone, dolomite and quartz, or a combination thereof.
• the core glue contains inert rock flour Feinststoff in an amount of 5 to 45 % by volume, in particular from 20 to 45% by volume, based on the total volume of hydraulic binder and fines contained in the core glue.
• the very fine material contains at least one hydraulically active material.
• the superfine contains at least one hydraulically active, synthetically produced substance and/or one hydraulically active natural substance.
• the fines contain at least one hydraulically active material selected from the group consisting of blast furnace slag, microsilica and fly ash, or a combination thereof.
• the very fine material contains microsilica.
• the finest material particularly preferably consists of a hydraulically active material, in particular microsilica.
• the core size particularly preferably contains hydraulically active fines, in particular microsilica, in an amount of 5 to 20% by volume, in particular 8 to 15% by volume, based on the total volume of hydraulic binder and fines contained in the core size.
• the finest material contains inert rock powder selected from the group consisting of limestone powder, dolomite powder and quartz or a combination thereof in an amount of 10 to 25% by volume, based on the total volume of hydraulic binder contained in the core size and Fines and (b) hydraulically active material selected from the group consisting of blast furnace slag, microsilica and fly ash, or a combination thereof, in an amount of 8 to 15% by volume based on the total volume of hydraulic binder and fines contained in the core size.
• inert rock powder selected from the group consisting of limestone powder, dolomite powder and quartz or a combination thereof in an amount of 10 to 25% by volume, based on the total volume of hydraulic binder contained in the core size and Fines
• hydraulically active material selected from the group consisting of blast furnace slag, microsilica and fly ash, or a combination thereof, in an amount of 8 to 15% by volume based on the total volume of hydraulic binder and fines contained in the core size.
• the superfine consists of (a) inert rock powder selected from the group consisting of limestone powder, dolomite powder and quartz or a combination thereof in an amount of 10 to 25% by volume, based on the total volume of hydraulic material contained in the core glue binder and fines and (b) hydraulically active material selected from the group consisting of blast furnace slag, microsilica and fly ash, or a combination thereof (especially microsilica) in an amount of 8 to 15% by volume, based on the total volume of hydraulic binder and fines contained in the core size.
• binder selected from the group consisting of limestone powder, dolomite powder and quartz or a combination thereof in an amount of 10 to 25% by volume, based on the total volume of hydraulic material contained in the core glue binder and fines
• hydraulically active material selected from the group consisting of blast furnace slag, microsilica and fly ash, or a combination thereof (especially microsilica) in an amount of 8 to 15% by volume, based on the total volume of hydraulic binder and fines contained in the core
• hydraulic binders are any binders that form strength-forming hydrate phases with the addition of water and, if appropriate, other components. It is preferably provided that the hydraulic binder in step a. and/or step b. is selected from the group consisting of cement, hydraulically active additives, latent hydraulic or pozzolanic additives, silicate binders, or a combination thereof.
• hydraulic binders are also to be understood as meaning geopolymeric binders.
• Geopolymeric binders are, in particular, slag-based geopolymeric binders, rock-based geopolymeric binders, fly ash-based geopolymeric binders (i.e. alkali-activated fly ash and/or slag/fly ash-based), aluminum silicate binders (alkali-activated aluminum silicates) and ferro-sialate-based geopolymeric binder.
• Such geopolymeric binders are fundamentally known and familiar to the person skilled in the art.
• Geopolymeric binders can be used either as the sole hydraulic binder or in combination with other hydraulic binders, especially in combination with cement.
• the hydraulic binder in step a. and/or step b. is selected from the group consisting of cement, fly ash, microsilica, blast furnace slag, natural or artificial pozzolan, geopolymers, metakaolin, calcined clays, or a combination thereof.
• the hydraulic binder in step a. and/or step b. Cement can be from the group consisting of the classes CEM I and CEM IVA according to EN 197-1, or a combination thereof.
• the core glue contains at least 350 kg/m 3 , in particular 350 to 1000 kg/m 3 , in particular 500 to 1000 kg/m 3 , based on the total dry weight of the core mixture, of hydraulic binder. It is furthermore preferably provided that the core glue contains hydraulic binder, in particular cement, in an amount of 60 to 95% by volume, in particular from 65 to 80% by volume, based on the total volume of hydraulic binder and fines contained in the core glue , contains.
• the facing glue contains at least a hydraulic binder and water. It is preferably provided that the facing glue, based on the total dry weight of the facing mixture, contains 350 to 1000 kg/m 3 , in particular 500 to 1000 kg/m 3 , of hydraulic binder.
• the face glue and the core glue can contain the same or different hydraulic binders.
• the end glue and the core glue contain the same hydraulic binder.
• the hydraulic binder of the face glue and the core glue is cement, in particular a cement selected from the group consisting of classes CEM I and CEM IVA according to EN 197-1, or a combination thereof.
• the front glue contains hydraulic binder, in particular cement, in an amount of 40 to 91% by weight, in particular 50 to 70% by weight, based on the total dry weight of the front glue.
• the core mix also contains aggregate with an average diameter d50, determined according to ISO 13320:2009 and/or EN 12620, greater than 100.0 ⁇ m.
• the aggregate has an average diameter that is larger than the average diameter of the hydraulic binder. This has the advantage that the additive improves the compressibility of the core mixture when the excess water is pressed out of the face mixture layer and/or promotes the pressing of the water out of the face mixture layer into the core mixture layer.
• the aggregate contained in the core mixture is a mixture containing organic and/or inorganic substances, wherein the organic and/or inorganic substances are optionally selected from the group consisting of coarse rock flour, including mineral aggregate Aggregate according to EN 12620, ceramics, glass, synthetic fibres, natural fibers and biological components, in particular grass, or a combination thereof.
• the aggregate contained in the core mixture is a rock aggregate according to EN 12620, preferably a rock aggregate according to EN 12620 based on quartz, basalt, granite, lime, lime chips or mixtures thereof.
• the aggregate contained in the core mixture and/or facing mixture is an aggregate according to EN 12620, which has an average diameter of 0.101 mm to 5.000 mm, in particular 0.125 mm to 5.000 mm, preferably 0.250 mm to 5.000 mm.
• a mixture is used as the aggregate, the composition of which is optimized by means of methods for determining the optimal grading curve in such a way that a minimum cavity for aggregate mixtures with a very small particle size that is larger than the average diameter d50 is determined according to ISO 13320:2009, of the hydraulic binder.
• water binding mean value
• the core mixture introduced into the mold before pressing according to step c. a water binder average value (W/B) of 0.10 to 0.40, preferably 0.12 to 0.20, based on the ratio of water to the sum of hydraulic binder and fines with an average diameter of 1.0 to 100 .0 pm, in particular from 1.0 to 30.0 pm.
• W/B water binder average value
• the core mixture introduced into the mold after pressing according to step c. has an average water-binding value of 0.20 to 0.45, preferably 0.21 to 0.28, based on the ratio of water to the sum of hydraulic binder and fines with an average diameter d50 determined according to ISO 13320:2009 of 1.0 to 100.0 pm, in particular from 1.0 to 30.0 pm.
• the core mixture introduced into the mold after the pressing in step c. an average water binding value of 0.22 to 0.24.
• the method according to the invention provides that water is pressed from the face mixture layer into the core mixture layer.
• the W/B value of the layer of facing mixture is generally lower after pressing than before pressing.
• the W/B value of the core mix layer is usually higher after pressing than before pressing.
• the core mixture introduced into the mold before pressing according to step c. has an average water-binding value that is the same as or lower than the average water-binding value of the facing mixture introduced into the mold before pressing according to step c.
• the core mixture introduced into the mold before pressing according to step c. an average water binding value that deviates by 15% or less from the facing mixture introduced into the mold before pressing according to step c), based on the average water-binding value of the facing mixture introduced into the mold before pressing according to step c).
• This design is particularly advantageous if UHPC concrete (ultra high performance concrete) is used as the facing layer.
• the step b The core mixture used is characterized by a relatively high degree of glue saturation (LSG).
• LSG is a measure of the degree to which the cavity specified by the aggregate is filled with binding agent. It can be calculated using the following formula (1):
• VL glue volume (percentage of water and fines ⁇ 100pm per m 3 concrete) [m 3 /m 3 ]
• VG.HP void content of the aggregate mixture 100pm in the pressed state [m 3 /m 3 ]
• VG,H,P can be calculated as follows:
• Vc.id-- idealized volume of aggregate mixture > lOOum without considering air volume [m 3 ]
• the press test with the hermetic press to determine the void content VG, P can be carried out as follows: • Amount of aggregate > 100 pm is poured into a press mold (eg laboratory hermetic press) and distributed as evenly as possible using a steel ruler or similar.
• a press mold eg laboratory hermetic press
• an LSG of 1 would be an ideal-typical state in which there is a maximum packing density.
• this maximum packing density is not usually achieved in practice, since in addition to a proportion of air voids, which can be assumed to be 1.0 to 1.5% by volume, the degree of compression or compressibility plays an important role .
• a significant increase in the strength of the multilayer panel in the hardened state can be achieved by increasing the LSG of the core mixture.
• increasing the LSG to values above 1.1 is disadvantageous for common core compounds, as this leads to a reduction the flexural strength of the multilayer panel. It has now been found that the method according to the invention enables a further increase in the characteristic flexural strength, specifically up to an LSG of the core mixture of around 1.5. As a result, greater strength can be achieved than was possible with known multi-layer panels.
• the amount of core glue contained in the core mixture is calculated in such a way that a degree of glue saturation for the core mixture, calculated according to formula (1), from 1.0 to 1.5, preferably from 1.1 to 1.4, results.
• a further advantage of the invention is that a high degree of compaction and/or a high packing density can be achieved even with a low glue layer thickness (LSD) of the core glue layer.
• Glue layer thickness (LSD) is the calculated LSD that results after pressing according to formula (2):
• VL volume of glue (volume of fines (largest particle size ⁇ 100 m) and water) [m 3 /m 3 ]
• VG.HP voids content of aggregate mix > 100 m in compacted state [m 3 /m 3 ] m g mass of aggregate mix > 100 ⁇ m per m 3 of concrete [kg/m 3 ]
• the amount of core glue contained in the core mixture is calculated in such a way that a glue layer thickness, calculated according to formula 2, is at most 30.0 ⁇ m, in particular at most 20.0 ⁇ m or from 3.0 to 20.0 ⁇ m , for the core glue layer.
• the end-mixture used in the process according to the invention contains at least the following components: i. containing at least
• the face mixture layer has, before the pressing according to step c. a consistency of at least consistency class F5 according to DIN 1045-2 and/or EN 206, in particular a consistency according to one of the consistency classes F5 or F6.
• the facing mixture based on the total dry weight of the facing mixture, contains 450 to 1250 kg/m 3 , in particular 600 to 1250 kg/m 3 , of facing glue.
• the endpaper contains fines.
• the end glue contains very fine material as a further component, in particular very fine material with an average diameter d50, determined according to ISO 13320:2009, of up to 100.0 ⁇ m.
• the face size contains fines with an average diameter of 1.0 to 100.0 gm in an amount of 5 to 50% by weight, preferably 15 to 45% by weight, in particular 20 to 45% % by weight based on the total dry weight of the end face glue.
• the end glue contains very fine material which has an average diameter d50, determined according to ISO 13320:2009, which is smaller than the average diameter d50, determined according to ISO 13320:2009, of the hydraulic binder and preferably in an amount of 5 to 50%, more preferably 15 to 45%, and most preferably 20 to 45% by weight based on the total dry weight of the face size.
• the face glue contains inert rock dust as the finest substance.
• the face size contains hydraulically active fines, in particular microsilica, in an amount of 5 to 20% by volume, in particular 8 to 15% by volume, based on the total volume of hydraulic binder and fines contained in the face size.
• the facing mixture used in the process according to the invention also contains additive.
• the aggregate that is suitable for the core mix is basically also suitable for the facing mix.
• the aggregate in the face mix has an average diameter that is greater than the average diameter of the hydraulic Binder, in particular greater than 100.0 pm.
• the aggregate contained in the facing mixture has an average diameter of 0.101 mm to 5.000 mm, in particular 0.125 mm to 5.000 mm or 0.250 mm to 5.000 mm.
• the aggregate contained in the facing mixture is a rock aggregate, in particular a rock aggregate based on quartz, basalt, granite, lime, lime chips or mixtures thereof. It is also advantageous if the aggregate contained in the facing mixture is a rock granule with an average diameter of 0.101 mm to 5.000 mm, in particular 0.125 mm to 5.000 mm or 0.250 mm to 5.000 mm.
• the aggregate is a mixture containing organic and/or inorganic substances, with the organic and/or inorganic substances optionally being selected from the group consisting of coarse rock flour, mineral aggregate including aggregate according to EN 12620, ceramics, glass, synthetic fibers , natural fibers and biological components, in particular grass, or a combination thereof.
• the aggregate is a mixture whose composition is optimized using methods for determining the optimal grading curve in such a way that there is a minimum cavity for aggregate mixtures with a micro-grain that is larger than the average diameter d50, determined according to ISO 13320:2009, of the hydraulic binder.
• the facing mixture preferably contains at least the following components: i. containing at least
• ingredients of the face mix in particular with regard to hydraulic binder, ultra-fine material, aggregate and additives, unless otherwise stated, the above information, in particular that stated above in connection with the core mixture, applies accordingly.
• the facing mixture introduced into the mold before the pressing according to step c. a water binding average value (W/B) of at most 0.60, preferably at most 0.40, preferably from 0.20 to 0.40, based on the ratio of water to the sum of hydraulic binder and fines with a mean diameter of 1.0 to 100.0 pm, in particular from 1.0 to 30 pm.
• W/B water binding average value
• the steps a. and b. of the process according to the invention can be carried out in the order given (first step a., then step b.) or in the reverse order (first step b, then step a.).
• the dry to earth-moist core mixture is applied in the mold to the flowable facing mixture layer that has already formed. This is the norm.
• Both the core mix and the face mix can also contain one or more additives according to EN 934.
• suitable additives which on the one hand improve the dispersion and wetting of the hydraulic binder, especially cement, and additives during the mixing process and on the other hand can reduce the frictional forces between the fine material components, can have a positive effect on the processing and compaction capacity.
• the core mixture and/or the facing mixture contains 0.01 to 3.0% by weight, based on the total dry weight of the hydraulic binder, of additives according to EN 934 as a further component.
• the additive is preferably selected from the group consisting of plasticizers, superplasticizers, stabilizers, air entraining agents, accelerators, retarders, shrinkage modifiers and sealants, or a combination thereof.
• the core mixture and/or the facing mixture preferably contains 0.01 to 3.0% by weight, based on the total dry weight of the hydraulic binder, of superplasticizer as a further component.
• the flow agent is preferably selected from the group consisting of surfactants, particularly naphthalene sulfonates and/or lignin sulfonates, and dispersing agents, particularly melamine resins, polycarboxylates and polycarboxylate ethers, or a combination thereof.
• a polycarboxylate, polyaryl ether or polycarboxylate ether is used as flow agent.
• the pressure during pressing according to step c. at least 0.5 N/mm 2 , in particular at least 10 N/mm 2 , preferably at least 15 N/mm 2 .
• the pressing preferably takes place according to step c. with a pressing time of 5 to 60 seconds, in particular 5 to 40 seconds or 5 to 15 seconds.
• the pressing according to step c. can take place in one pressing process or in at least two consecutive pressing processes with the same or different intensity.
• the pressing is preferably provided in a pressing process.
• the pressing takes place according to step c. in a hermetic press.
• the invention relates to a hydraulically bonded multi-layer panel which can be produced or is produced by the method according to the invention.
• the hydraulically bound multilayer board according to the invention can have any dimensions.
• the multilayer board according to the invention is a relatively large-sized hydraulically bonded multilayer board, for example a multilayer board having a length of at least 300, 400, 500, 600, 700 or 800 mm.
• the hydraulically bound multilayer board according to the invention has a length of 800 to 1200 mm.
• the hydraulically bound multilayer board according to the invention can have all the usual square dimensions and is not limited to large-format multilayer boards. However, the advantages of the invention are particularly evident in the production of large-format multilayer boards.
• the hydraulically bound multilayer board according to the invention preferably has an area of at least 0.16 m 2 , in particular from 0.18 to 1.44 m 2 , 0.32 to 1.44 m 2 , 0.18 to 0.83 m 2 or 0 .32 to 0.83 m 2 .
• Particularly preferred is a hydraulically-bonded multilayer board having an area of 0.32 to 1.44 m 2 .
• the hydraulically bonded multilayer board of the present invention is not limited in thickness and may have any thickness. However, the advantages of the invention are particularly evident in the production of relatively thin multi-layer boards. Accordingly, preference is given to a hydraulically bonded multi-layer panel which has a thickness of at most 40.0 mm, in particular from 15.0 to 40.0 mm.
• the hydraulically bound multi-layer board according to the invention also has a relatively high degree of compaction.
• the degree of compaction is the ratio between the calculated maximum raw density of the mixture of an idealized board without air and the measured raw density of the board produced after the pressing process.
• the degree of compaction is calculated in particular according to formula (3):
• the core mixture layer has a degree of compaction, determined according to formula (3), of from 0.93 to 0.99, in particular from 0.97 to 0.99.
• the hydraulically bound multilayer board according to the invention is also characterized by a relatively high packing density of the core mixture layer.
• Packing density is to be understood as meaning the packing density of all solids in the core layer mixture in the pressed state.
• the packing density can be calculated as follows:
• the core mixture layer has a packing density, determined according to formula (4), of 0.75 to 0.85, in particular 0.78 and 0.83.
• the hydraulically bound multilayer panel has a characteristic flexural strength, determined according to DIN EN 1339 after 7 days of hardening, of more than 7.5 N/mm 2 , in particular at least 8.5 N/mm 2 and particularly preferably of at least 10.0 N/mm 2 .
• Vw, s /Vp means the water requirement of the powder (or of the very fine material in the context of this invention) at the saturation point.
• Marquardt I. A mixture concept for self-compacting concrete on the basis of the volume parameters and water requirements of the starting materials, thesis, University of Rostock, 2001, is adopted and adapted for the present application.
• a certain amount of the dry powder was put into a mixer that is able to record changes in the mixing energy input or its power consumption.
• water was mixed in continuously at a constant rotational speed and the amount of water added was continuously measured using a flow meter.
• the peak of the mixer's power consumption which corresponds to the maximum shear resistance, indicates when the saturation point has been reached.
• the mixture becomes "earth-moist".
• the water content in the mixture can be given at any time i, usually as "volumetric water powder ratio" (V w ,i/V p ). At the saturation point, this corresponds to the water demand at the saturation point (V w , s /V p ).
• w s /b means the water binding average value at the saturation point and it relates to the ratio of water to the sum of hydraulic binding agent and fines within the meaning of the invention.
• V w ,s/V p or w s /b value indicates a lower void content or higher packing density.
• the solid glue compositions described above are particularly well suited for their use in the production process according to the invention. This is because the core size compositions according to the invention give the core mixture layer of the multilayer board excellent compressibility and strength with reduced water requirements.
• the face size compositions of the present invention impart excellent workability, strength and durability to the face layer of the multilayer board.
• a multilayer board was produced from the facing and core mixtures given above as follows:
• the prepared flowable facing mixture was introduced into an 800 mm 400 mm large hermetic press mold of the OCEM laboratory sliding table press 100 to type and distributed as evenly as possible in the mold.
• the layer thickness of the face mix after filling in the mold ie, the thickness of the face mix layer
• the prepared earth-moist core mix was then applied to the facing mix layer in a layer that was as homogeneous as possible (approx. 29 mm) using a funnel and a squeegee.
• the core mix layer and the face mix layer were pressed together in the hermetic press at a pressure of about 15.0 MPa for about 10 seconds.
• the multilayer panel obtained was demoulded immediately after pressing.
• the W/B value of the core mix layer was 0.159
• the W/B value of the face mix layer was 0.664.
• the core mixture layer had a layer thickness of 24 mm, and the facing mixture layer had a layer thickness of 6 mm.
• Multilayer board was 30 mm. Despite its relatively low thickness, the multi-layer panel had a characteristic flexural strength, determined according to DIN EN 1339 after 7 days of hardening, of 10.9 N/mm 2 and was characterized by excellent load-bearing capacity and outstanding serviceability.

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• 2020
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