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
  • 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
  • C04B28/001—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
  • 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
  • C04B2103/008—Flocking or deflocking agents
  • C04B2103/0081—Deflocking agents
• • 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
  • C04B2103/10—Accelerators; Activators
• • 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
  • C04B2111/00017—Aspects relating to the protection of the environment
• • 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
  • C04B2111/00025—Aspects relating to the protection of the health, e.g. materials containing special additives to afford skin protection

Definitions

• the invention relates to the field of construction materials, and more particularly to that of binders that can be used in construction.
• the invention relates to a formulation for a construction binder.
• the invention also relates to a process for preparing a construction binder, the construction binder as such and the use of such a binder in the production of construction materials.
• the building materials thus obtained also subject of the invention, provide summer comfort (e.g. passive regulation of hygrothermy) to the buildings that incorporate them.
• Cement is the second most consumed resource in the world, with more than 4 billion tons of materials produced each year in the world and this consumption is constantly increasing driven by the growing demand for housing and infrastructure.
• Cement is a generally hydraulic binder which, when mixed with water, hardens and solidifies. After hardening, the cement retains its strength and stability even when exposed to water.
• cements used by the world. However, all conventional cements contain a clinker at a percentage ranging from 5% for certain blast furnace cements to a minimum of 95% for Portland cement, which is the cement most widely used in the world today.
• Clinker results from the firing of a mixture composed of approximately 80% limestone and 20% aluminosilicates (such as clays). This cooking, the clinkerization, is generally done at a temperature of more than 1200°C, such a cement preparation process therefore involves high energy consumption. Additionally, the chemical conversion of limestone to lime also releases carbon dioxide. As a result, the cement industry generates around 8% of global CO2 emissions. Faced with this challenge, the industry and researchers are studying the possibilities of reducing the impact of carbon dioxide emissions generated by the cement industry.
• hemp for the production of mortar, coating, prefabricated hemp concrete elements allows optimal humidity regulation in addition to having very satisfactory insulating properties and its production has a very high carbon footprint.
• biobased building materials often have relatively weak mechanical properties, which limits their use to insulation, cladding or the formation of wall partitions subject to little mechanical stress.
• drying times, for example of hemp concrete are relatively long (e.g. greater than 5 days) which further limits their use.
• the object of the invention is to remedy the drawbacks of the prior art.
• the aim of the invention is to propose a construction binder making it possible to obtain a construction material capable of thermal and water regulation while retaining mechanical properties adapted to the constraints of modern constructions.
• the invention has for the purpose of proposing, for certain applications, such a material additionally provided with rapid setting.
• the invention also aims to provide a process for manufacturing a construction binder that makes it possible to reduce the emission of greenhouse gases, such as the carbon dioxide emitted during the preparation of such a construction material. construction, while preserving the suitable mechanical characteristics of said material and giving it hygrothermal regulation properties.
• the invention relates in particular to a construction binder comprising a raw clay matrix, a deflocculating agent and an activating composition, characterized in that:
• the raw clay matrix comprises at least one raw clay from the smectite family
• At least one raw clay from the smectite family represents at least 20% by weight of the construction binder; and the building binder comprises less than 15% by weight of Portland cement.
• the invention relates to a construction binder comprising a raw clay matrix, a deflocculating agent and an alkaline activating composition, characterized in that:
• the building binder comprises less than 15% by weight of Portland cement.
• a building binder according to the present invention provides water buffering capacities capable of improving the comfort of the inhabitants by thermal and water regulation.
• the construction binder according to the invention is intended to replace, totally or in part, Portland cement.
• the inventors have shown that the presence, at least at a given concentration, of smectite in a construction binder according to the invention makes it possible to achieve very good water buffering capacity values which are not achievable under these conditions. with other raw clays alone such as kaolinite.
• the construction binder makes it possible to achieve mechanical performance identical to Portland cement (eg class C12/15; C20/25 or C25/30) while reducing by 30 to 85% the greenhouse gas emissions, and by providing comfort to residents through thermal and water regulation. Also, it includes little to no Portland cement. Indeed, as illustrated in the examples, the presence of Portland cement leads to a reduction in the water buffer value.
• Portland cement eg class C12/15; C20/25 or C25/30
• the building binder may optionally include one or more of the following characteristics, alone or in combination:
• the raw clay matrix comprises a mixture of at least two types of clay.
• the raw clay matrix comprises at least one raw clay from the smectite family and at least one other clay selected from: Illite; Kaolinite; Vermiculite; Chlorite; muscovite; Halloysite; Sepiolite or Attapulgite.
• a combination of clay makes it possible to obtain better results in terms of water buffering capacity and mechanical resistance.
• the raw clay matrix comprises at least one clay having a specific surface at least equal to 100 m 2 /g, for example as measured according to standard NFP 94-068, a specific surface at least equal to 150 m 2 /g; a specific surface at least equal to 200 m 2 /g; or a specific surface at least equal to 250 m 2 /g. More preferably, the raw clay matrix comprises at least two clays having a specific surface at least equal to 100 m 2 /g, a specific surface at least equal to 150 m 2 /g; a specific surface at least equal to 200 m 2 /g; or a specific surface at least equal to 250 m 2 /g.
• the specific surface can be measured using the protocols described in the standards NFP 94-068, or NF EN 933-9+A1 or ISO 9277:2010. More preferably, the construction binder will comprise at least 20% by weight of a clay having such specific surface areas, even more preferably less than 40% by weight.
• the building binder allows the preparation of building materials having water buffer capacities (MBV) greater than or equal to 1,3.
• MBV water buffer capacities
• the green clay matrix can be present from 40% to 70%, preferably from 40% to 60% by weight of the building binder.
• the construction binder comprises at least 20% by weight of the calcined metal oxide composition.
• the activation composition comprises at least 40% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two valence electrons.
• the activation composition may in particular comprise at least 50% by weight of a metal oxide corresponding to the oxide of a metal having at least two valence electrons. The presence of such a metal oxide at these concentrations in the activating composition makes it possible to increase the water buffering capacity value.
• the construction binder comprises at least 10% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two valence electrons.
• the at least 10% by weight may correspond to several different metal oxides.
• the metal oxides formed with a metal having at least two valence electrons may come from several sources.
• these metal oxides will be contained in the activation composition and/or in the calcined metal oxide composition.
• the construction binder comprises at least 15% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two valence electrons, more preferably at least 20% by weight; even more preferably at least 25% by weight, for example at least 30% by weight.
• the construction binder may comprise less than 50% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two valence electrons.
• the construction binder may comprise between 15% by weight and 40% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two valence electrons.
• the construction binder combined with water and aggregates has a water buffer value, measured no earlier than 10 days after manufacture and preferably 28 days, greater than or equal to 0.75, preferably greater than or equal to 1, more preferably greater than or equal to 1.2 and even more preferably greater than or equal to 1.5.
• the deflocculating agent is an organic compound.
• the deflocculation agent comprises a lignosulphonate, a polyacrylate, a humate or a mixture thereof. It comprises excavated earth comprising at least a part of the raw clay matrix. The excavated earth can then be considered as excavated clay soil.
• It further comprises a composition of at least 20% by weight of calcined aluminosilicates or in that the composition of metal oxides comprises at least 20% of aluminosilicates.
• the invention relates to a construction material capable of being formed from a construction binder according to the invention, comprising:
• the water buffer value can be measured according to the methodology for measuring MBV values as described in the description.
• the invention also relates to a construction material formed from a construction binder according to the invention, comprising at least 2% by weight of at least one raw clay from the smectite family, and less 3.75% by weight of Portland cement
• the latter may optionally include one or more of the following characteristics, alone or in combination:
• It preferably comprises less than 2% Portland cement, more preferably less than 0.1%, even more preferably it does not comprise Portland cement
• It comprises at least 5% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two valence electrons.
• It has a minimum compressive strength on cylinders at 1 day as measured by standard NF EN 206-1 greater than or equal to 2 MPa. For example, it may have a minimum compressive strength on cylinders at 28 days as measured by standard NF EN 206-1 greater than or equal to 2 MPa. In addition, it may have a minimum compressive strength on cylinders after 28 days as measured by standard NF EN 206-1 of less than or equal to 20 MPa.
• the invention relates to a prefabricated element capable of being formed from a construction binder according to the invention, said prefabricated element: - having a face with an area of at least 1 m 2 and a thickness of between 0.3 cm and 20 cm;
• the water buffer value can be measured according to the methodology for measuring MBV values as described in the description.
• the invention also relates to a prefabricated element formed from a construction binder according to the invention, having a face with an area of at least 1 m 2 and preferably a thickness of between 0, 3cm and 20cm; comprising at least 5% by weight of at least one raw clay of the smectite family, and comprising less than 3.75% by weight of Portland cement.
• the latter comprises at least 2% by weight of a composition of calcined metal oxides.
• the invention relates to a method for preparing a construction material comprising the following steps:
• a building binder comprising a raw clay matrix comprising at least one raw clay from the smectite family, a deflocculating agent and an activating composition; the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder; and the construction binder comprising less than 15% by weight of Portland cement,
• the invention relates to a method for producing a prefabrication element prepared from a construction binder, said construction binder comprising a raw clay matrix, an activating composition and a deflocculation agent , said method comprising:
• a construction binder comprising a raw clay matrix comprising at least one raw clay from the smectite family, a deflocculating agent and an activating composition; the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder; and the building binder comprising less than 15% by weight of Portland cement.
• step of curing comprising a heat treatment of the mixture, preferably at a temperature less than or equal to 100° C., for a period comprised between 2 hours and 23 hours.
• the invention relates to a method for producing a prefabrication element prepared from a construction binder, said construction binder comprising a raw clay matrix, an alkaline activating composition and a deflocculation agent, said method comprising:
• a construction binder comprising a raw clay matrix comprising at least one raw clay from the smectite family, a deflocculating agent and an alkaline activating composition; the building binder comprising from 2% to 40% by dry weight of the alkaline activating composition; the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder; and the construction binder comprising less than 15% by weight of Portland cement,
• step of curing comprising a heat treatment of the mixture, preferably at a temperature less than or equal to 100° C., for a period comprised between 2 hours and 23 hours.
• these prefabrication elements can present, after curing times of twenty-three hours or less, mechanical properties of concretes at least equivalent or even superior to the mechanical properties of concretes derived from cements commonly used in the construction field.
• the invention relates to a construction material formed or likely to be formed from a construction binder according to the invention.
• the construction material may optionally include one or more of the following characteristics, alone or in combination:
• It includes diatom frustules or plant fibers, preferably hemp.
• It has a water buffer value greater than or equal to 0.75, preferably greater than or equal to 1, preferably measured at the earliest 10 days after manufacture.
• the building material has a minimum compressive strength on cylinders at 1 day as measured by standard NE EN 206-1 greater than or equal to 2 MPa, preferably greater than or equal to 3 MPa, preferably greater than 5 MPa.
• the building material has a minimum resistance to compression on cylinders at 7 days as measured by standard NF EN 206-1 greater than or equal to 8 MPa, preferably greater than or equal to 10 MPa.
• the invention relates to a prefabricated element capable of being formed from a construction binder according to the invention and having a face with an area of at least 1 m 2 and a thickness between 0.3 cm and 20 cm.
• Such a prefabricated element advantageously has a water buffer value measured at 10 days greater than or equal to 0.75, preferably greater than or equal to 1, more preferably greater than or equal to 1.2 and even more preferably greater than or equal to equal to 1.5.
• Such a prefabricated element advantageously comprises less than 3.75% by weight of Portland cement.
• Such a prefabricated element advantageously comprises at least 5% by weight of at least one raw clay from the smectite family.
• Such a prefabricated element will be particularly suitable for use inside habitats. Indeed, a large exchange surface, combined with a high water buffer value will allow better regulation. In addition, the thickness can be selected according to the desired level of regulation.
• FIG. prefabrication prepared from a construction binder according to the invention.
• the term “% by weight” in connection with the raw clay matrix, the binder or the building material must be understood as being a proportion relative to the dry weight of the binder or the building material.
• the dry weight corresponds to the weight before the addition of water, for example, necessary for the formation of a building material.
• the term "Dehydrated” within the meaning of the invention corresponds to a formulation comprising a reduced quantity of water and for example a water content of less than 20% by weight, preferably less than 10%, more preferably less than 5 %, more preferably less than 2% and for example less than 1% by weight.
• the water content can be measured by any method known to the state of the art. It can for example be measured according to the NF P 94 050 standard of September 1995 “Determination of the water content by weight of materials: Steaming method”.
• clay matrix means one or more rocky materials based on silicates and/or aluminosilicates of lamellar structure, said clay matrix being composed of fine particles generally originating from the alteration of silicates with a three-dimensional framework, such as the feldspars.
• a clay matrix may thus comprise a mixture of such rocky materials which may for example consist of kaolinite, illite, smectite, bentonite, chlorite, vermiculite, metakaolin or mixtures thereof.
• unfired clay matrix corresponds within the meaning of the invention to a clay matrix that has not undergone a calcination step. In particular, that is to say that it has not undergone any prior heat treatment.
• a raw clay matrix may preferably comprise a mixture of rocky materials which may for example consist of kaolinite, illite, smectite, bentonite, chlorite, vermiculite, or mixtures thereof.
• a "deflocculating agent” or “deflocculating agent” may correspond to a compound which, in aqueous suspension, will dissociate aggregates and colloids. Deflocculating agents have for example been used in the context of drilling or oil extraction to make the clay more fluid and facilitate extraction or drilling.
• activation composition may correspond to a composition having the function of accelerating the formation of a compact structure, thus increasing the mechanical strength of the materials incorporating such an activation composition.
• an “alkaline activating composition” comprises at least one base, such as a weak base or a strong base.
• composition of metal oxides can refer within the meaning of the invention to a composition comprising metal oxides such as aluminates.
• the composition of metal oxides comprises more than 25% by weight of metal oxides, preferably more than 30% by weight of metal oxides, more preferably more than 40% by weight of metal oxides and even more preferably more than 45% by weight of metal oxides.
• the metal oxide composition comprises more than 2% by weight of aluminate, preferably more than 5% by weight of aluminate, more preferably more than 7% by weight of aluminate and even more preferably more than 10% by weight of aluminate.
• the metal oxides may correspond to, or include, alkaline earth metal oxides.
• the metal oxide composition may comprise more than 10% by weight calcium oxide, preferably more than 20% by weight calcium oxide, more preferably more than 25% by weight calcium oxide and even more preferably more than 30% by dry weight of calcium oxide.
• the composition of metal oxides may include chemical species that are not metal oxides.
• the metal oxide composition may comprise metalloid oxides with, for example, more than 10% by weight of metalloid oxide, preferably more than 20% by weight of metalloid oxide, more preferably more than 25% by weight of metalloid oxide and even more preferably more than 30% by weight of metalloid oxide. These mass concentrations can easily be measured by a person skilled in the art using conventional techniques for assaying metal oxides or metalloid oxides.
• composition of metal oxides refers to a composition comprising more than 50%, preferably more than 70%, more preferably more than 80% and even more preferably more than 90% of metal oxides and/or metalloid oxides, including aluminates.
• a composition of metal oxides will correspond to a slag from metallurgy, such as a blast furnace slag or even to fly ash.
• the “metal oxide composition” is a calcined metal oxide composition. That is to say, it has undergone a high temperature stage.
• This high temperature step can be natural or artificial, in this case it is a high temperature treatment.
• the high temperature step can for example correspond to a treatment at a temperature greater than or equal to 500° C., preferably greater than or equal to 750° C. and more preferably greater than or equal to 900° C.; and even more preferably above 1000°C.
• binder or "construction binder” within the meaning of the invention can be understood as a formulation making it possible to ensure the agglomeration of materials between them, in particular during the setting, then the hardening of a construction material. .
• the binder according to the invention is in particular a hydraulic binder, that is to say that the hardening takes place in contact with water.
• Portland cement corresponds to a hydraulic binder composed mainly of hydraulic calcium silicates, the setting and hardening of which is made possible by a chemical reaction with water.
• Portland cement generally contains at least 95% clinker and at most 5% secondary constituents such as alkalis (Na 2 O, K 2 O), magnesia (MgO), gypsum (CaSC ⁇ 2 H 2 O) or various traces of metals.
• a "construction material” within the meaning of the invention generally corresponds to elements comprising the constituents of the binder as well as aggregates and other additives.
• a building material within the meaning of the invention meets the criteria of standard NF EN 206-1. It can take different forms such as mortar, concrete or prefabricated elements such as concrete blocks.
• a "quick-setting construction material” may in particular take the form of a construction material which, 24 hours after the addition of water, has a minimum resistance to compression on cylinders as measured by standard NF EN 206-1 greater than or equal to 2 MPa; preferably greater than or equal to 3 MPa; more preferably greater than or equal to 5 MPa.
• air entrainer corresponds to an adjuvant intended to be incorporated into a construction binder according to the invention and whose main function is to generate porosities of homogeneous size within the construction binder once the setting of this one finished.
• an adjuvant can for example correspond to surfactants such as alkyl ether sulphates.
• hydro buffer value or “MBV” for “moisture buffer value” according to Anglo-Saxon terminology, represents the capacity of a material to exchange humidity with its environment. It allows to estimate the hygrothermal behavior dynamics of the material in question and is used to determine the thermal comfort in the field of construction and more particularly the regulation of the interior humidity of a room or a building.
• the MBV is expressed in g/m 2 .%RH and indicates the average quantity of water which is exchanged by sorption or desorption when the surfaces of the material are subjected to variations in relative humidity (RH) over a given time.
• the water buffer value can be measured by any method known to those skilled in the art.
• the person skilled in the art may refer to the method described in “Durability and hygroscopic behavior of biopolymer stabilized earthen construction materials” Construction and Building Materials 259 (2020).
• the samples may be placed in a climatic chamber at 23° C. and 33% relative humidity and are left until they have a constant mass (for example a climatic chamber model MHE 612). Under these conditions, the samples are equilibrated after 15 days of storage. The samples are then exposed to cycles of high humidity (75% RH for 8 h) then a cycle of low relative humidity (33% RH for 16 h). The samples are weighed at regular intervals with a laboratory balance accurate to 0.01 g. After two stable cycles, the samples left the climatic chamber.
• Am is the change in mass of the sample due to the change in relative humidity
• S is the total exposure area
• A% RH is the difference between the humidity levels.
• substantially equal within the meaning of the invention corresponds to a value varying by less than 20% with respect to the compared value, preferably by less than 10%, even more preferably by less than 5%.
• prefabricated element or "prefabricated elements” within the meaning of the invention may correspond to construction elements which have undergone a curing step such as elements of the concrete block type which can be combined modular way to make a building.
• prefabricated elements can include a reinforcement (eg: beams, panels, stairs) or not (eg: blocks, interjoists, tiles, plates).
• the expression “specific surface” within the meaning of the invention may correspond to a clay adsorption capacity. It can be measured by the French standard NFP 94-068 indicating a methodology allowing the determination of the methylene blue value of a soil or a rocky material by means of the methylene blue test.
• the specific surface can also be measured according to standard NE EN 933-9+A1. Indeed, there is a correlation, demonstrated as early as 1950 by Dyal and Hendricks, 1950, between the adsorption of the methylene blue molecule (in g/100 g) via electrostatic interactions, and surface measurements specific to the clay material. In addition, the measurement of the specific surface can also be measured via the BET method (Brunauer, Emmett and Teller).
• This method can preferably be implemented according to the recommendations of the ISO 9277:2010 standard. Briefly, the specific surface area is estimated from the amount of nitrogen adsorbed in relation to its pressure at the boiling temperature of liquid nitrogen and under normal atmospheric pressure. The information is interpreted according to the model of Brunauer, Emmett and Teller (BET method).
• BET method Brunauer, Emmett and Teller
• excavated clay soil corresponds in the sense of the invention to clay soil obtained following a stage where the soil has been dug, for example during leveling and/or earthworks operations, with a view to building, build or fill.
• excavated clay soil may correspond to quarry fines, dredged sediments, drilling/washing muds.
• these fines, sludges or sediments comprise clays having a specific surface greater than 100 m 2 /g, preferably greater than 200 m 2 /g or even clays of the smectite family; preferably at contents greater than 20% by weight of the clay matrix, then they are particularly suitable for the present invention.
• the excavated clay soil may or may not be moved outside the production site.
• the excavated earth is used on the production site or at a distance of less than 200 km, preferably less than 50 km.
• the clayey earth excavated in the context of the invention is raw excavated clayey earth, that is to say that it has not undergone a calcination step. In particular, that is to say that it has not undergone any prior heat treatment. For example, this corresponds to a clay soil which has not undergone a temperature rise above 300°C, preferably above 200°C and more preferably a temperature above 150°C.
• the raw clay earth can undergo a heating step requiring a rise in temperature generally of substantially equal to 150° C. but no calcination step.
• a calcination step could for example correspond to a heat treatment at more than 600° C. for at least one hour.
• Clay as conventionally used has a relatively constant particle size profile with sizes below 2 ⁇ m.
• Excavated clay soil can have different grain size profiles.
• an excavated clay soil may comprise particles of a size greater than 2 ⁇ m, preferably greater than 20 ⁇ m, preferably greater than 50 ⁇ m and for example greater than 75 ⁇ m as determined according to the ASTM standard. D422-63.
• the excavated clay soil does not contain any aggregate of a size greater than 2 cm as determined according to standard NE EN 933-1.
• the field of construction must evolve to increase its productivity while responding to new societal challenges.
• manufacturers have proposed so-called more ecological cement mixtures comprising, for example, 50% Portland cement, 30% dairy and 20% fly ash; high-performance concretes have also been proposed which may include superplasticizers, such as self-compacting concretes or else cellular concretes comprising gypsum, lime, cement and sand.
• a binder according to the invention consists of a raw clay matrix, which has not undergone a calcination step, an energy-intensive step which also generates the emission of greenhouse gases and more particularly carbon dioxide. carbon.
• the invention relates in particular to a building binder comprising a raw clay matrix, a deflocculation agent and an activating composition, characterized in that the raw clay matrix comprises at least smectite, montmorillonite or bentonite , preferably more than 10% by weight of a clay of the smectite family.
• a method according to the invention makes it possible to manufacture construction elements from a binder comprising a high concentration of raw clay matrix (generally greater than 10%, preferably greater than or equal to 20% ), having a mechanical strength at 28 days greater than 10 MPa, preferably greater than 12 MPa and having an MBV greater than 0.7, preferably greater than 1, and more preferably greater than 1.3 and so even more preferably greater than 1.5.
• a binder comprising a high concentration of raw clay matrix (generally greater than 10%, preferably greater than or equal to 20% ), having a mechanical strength at 28 days greater than 10 MPa, preferably greater than 12 MPa and having an MBV greater than 0.7, preferably greater than 1, and more preferably greater than 1.3 and so even more preferably greater than 1.5.
• construction binder compositions making it possible to form construction materials having a minimum resistance to compression on cylinders as measured by standard NF EN 206-1, at 28 days greater than or equal to 12 MPa , preferably greater than 15 MPa and a water buffer value greater than or equal to 0.7, preferably greater than or equal to 1, more preferably greater than or equal to 1.2 and even more preferably greater than or equal to 1.5.
• NF EN 206-1 standard NF EN 206-1
• the raw clay matrix may for example comprise at least one mineral species selected from: Illite, Kaolinite, Smectite, Bentonite, Vermiculite, Chlorite, Muscovite, Halloysite, Sepiolite, and Attapulgite.
• the raw clay matrix comprises smectite, preferably Montmorillonite.
• the clay matrix comprises at least 10% by weight of smectite, preferably montmorillonite, more preferably at least 20% by weight.
• the inventors have shown that, if the raw clay matrix comprises at least one raw clay from the smectite family and in particular when the at least one raw clay from the smectite family represents more than 10% by weight of the building binder, preferably at least 20% by weight of the building binder, then the building binder allows the preparation of building materials combining mechanical properties and water buffering capacity.
• the smectite family includes montmorillonites and bentonite.
• the raw clay matrix comprises at least two types of clay selected from: Illite; Smectite preferably Montmorillonite; Kaolinite; Bentonite; Vermiculite; Chlorite; muscovite; Halloysite; Sepiolite or Attapulgite.
• the raw clay matrix comprises at least one mineral species selected from: Kaolinite, Illite, Smectite, Bentonite, Chlorite and Vermiculite.
• Table 1 below presents the chemical characteristics of these mineral species.
• a construction binder according to the invention will comprise at least two different types of clay and will comprise smectite.
• the type of clay can be determined by methods known to those skilled in the art. In particular, it will be possible to use X-ray diffractometry. For example, the following conditions may be used:
• Diffractometer for example a BRUKER D8 ADVANCE (Bragg-Brentano Geometry); for example with the following settings: Copper Tube ( ⁇ Ka1 ⁇ 1 .54 ⁇ ) Generator power: 40 kV, 40 mA; Primary optics: fixed slit 0.16°; Soller's cleft 2.5°; Secondary optics: Soller slit 2.5°; LynXeye XE-T Detector
• a construction binder according to the invention comprises at least 10% by weight of raw clay matrix, preferably at least 20% by weight of raw clay matrix, more preferably at least 30% by weight of clay matrix raw and even more preferably at least 40% by weight of raw clay matrix. For example, at least 50% by weight of raw clay matrix or at least 60% by weight of raw clay matrix. Furthermore, preferably, a construction binder according to the invention comprises at most 80% by weight of raw clay matrix, more preferably at most 70% by weight of raw clay matrix.
• a construction binder according to the invention may comprise between 20 and 80% by weight of raw clay matrix, preferably between 30 and 80% by weight or between 40 and 80% by weight of raw clay matrix, more preferably between 40 and 70% by weight of raw clay matrix.
• the raw clay matrix of a construction binder according to the invention comprises at least 20% by weight of smectite, for example at least 30% by weight of smectite, preferably at least 40% by weight of smectite , more preferably at least 50% by weight smectite and even more preferably at least 60% by weight smectite.
• a clay matrix according to the invention may comprise between 20 and 80% by weight of smectite, preferably between 30 and 70% by weight of smectite or between 40 and 60% by weight of smectite, more preferably between 40 and 60% by weight of smectite.
• the smectite may be Montmorillonite.
• the raw clay matrix of a construction binder according to the invention comprises at least one raw clay from the smectite family and at least one other raw clay selected from Kaolinite, Illite, Chlorite and Vermiculite. Even more preferably, the raw clay matrix of a building binder according to the invention comprises smectite and at least one other raw clay selected from Kaolinite, Illite, Bentonite, Montmorillonite, Chlorite and Vermiculite.
• the construction binder comprises excavated earth comprising the raw clay matrix. It may comprise at least 2% by weight of silt particles, preferably at least 4% by weight, more preferably at least 6% by weight.
• the silt particles are in particular particles having a diameter of between 2 ⁇ m and 125 ⁇ m, preferably between 2 and 50 ⁇ m.
• the excavated clay soil may advantageously have been pretreated, said pretreatment being selected from: grinding, sorting, sieving and/or drying of the excavated clay soil.
• the pre-processing can for example comprise a fractionation.
• the building binder according to the invention has the advantage of being able to contain a high quantity of raw clay matrix without this altering either the hygroscopic properties or the mechanical properties of the building materials, making it possible to produce construction materials that, in addition to water buffering capabilities, have in some cases an improved setting time compared to commonly used construction materials.
• the deflocculation agent is in particular a nonionic surfactant such as a polyoxyethylene ether.
• a nonionic surfactant such as a polyoxyethylene ether.
• the polyoxyethylene ether can for example be selected from: a poly(oxyethylene) lauryl ether.
• the deflocculating agent can also be an anionic agent such as an anionic surfactant.
• the anionic agent can be selected from: alkylaryl sulphonates, aminoalcohols, fatty acids, humates (e.g. sodium humates), carboxylic acids, lignosulphonates (e.g. sodium lignosulphonates), polyacrylates, carboxymethylcelluloses and mixtures thereof.
• the deflocculation agent can also be a polyacrylate. It can then be selected, for example, from sodium polyacrylate and ammonium polyacrylate.
• the deflocculation agent can also be an amine selected, for example, from: 2-amino-2-methyl-1-propanol; mono-, di- or triethanolamine; isopropanolamines (1 - Amino-2-propanol, diisopropanolamine and triisopropanolamine) and N-alkylated ethanolamines.
• the deflocculation agent can be a mixture of compounds, such as a mixture comprising at least two compounds selected from: nonionic surfactant, anionic agent, polyacrylate, amine and organophosphorus compound.
• the deflocculating agent may be an organic deflocculating agent.
• an organic deflocculating agent comprises at least one carbon atom and preferably at least one carbon-oxygen bond.
• the deflocculation agent is selected from: a lignosulphonate (e.g. sodium lignosulphonate), a polyacrylate, a humate, a polycarboxylate such as an ether polycarboxylate, and mixtures thereof. More preferably, the deflocculating agent comprises humate, lignosulphonate and/or polyacrylate.
• the deflocculating agent is preferably in powder form (such as a salt).
• the invention cannot be limited to the deflocculating agents mentioned above. Any type of deflocculating agent known to those skilled in the art can be used instead of said deflocculating agents mentioned above.
• the deflocculation agent represents at least 0.5% by weight of the raw clay matrix, preferably at least 1% by weight of the raw clay matrix, more preferably at least 2% by weight of the matrix raw clay, even more preferably at least 3% by weight of the raw clay matrix, and for example at least 4% by weight of the raw clay matrix.
• the deflocculation agent can represent at most 5% by weight of the raw clay matrix.
• the deflocculating agent represents at least 0.1% by weight of the building binder, preferably at least 0.5% by weight of the building binder.
• the deflocculating agent may represent at most 5% by weight of the building binder, preferably at most 4% by weight of the building binder, more preferably at most 3% by weight of the building binder, and even more preferably at most 2% by weight of the building binder.
• a construction binder according to the invention can then be used in combination with an activating composition to form a material with advantageous hygrothermal and mechanical properties.
• a certain level of deflocculation agent should not be exceeded in order to avoid degradation of the mechanical properties of the construction material. Too high a concentration of deflocculation agent in combination with the raw clay matrix and the activation composition may degrade the mechanical performance and/or the performance of MBV.
• the activating composition is preferably an alkaline activating composition.
• An alkaline activating composition includes at least one base, such as a weak base or a strong base.
• the alkaline activating composition may preferably comprise one or more compounds having a pKa greater than or equal to 8, more preferably greater than or equal to 10, more preferably greater than or equal to 12, even more preferably greater than or equal to equal to 14.
• the alkaline activating composition can include sulphates, hydroxides, carbonates, lactates, organophosphates or combinations thereof.
• the alkaline activating composition comprises hydroxides.
• the alkaline activating composition can comprise a mixture of sodium/calcium sulphate and of sodium/calcium chloride.
• the alkaline activating composition comprises carbonates.
• the alkaline activating composition can comprise a mixture of silicate of sodium or potassium and sodium or potassium carbonate.
• the activating composition can also comprise an alkaline compound, preferably a strong base.
• the activation composition comprises an oxide of a metal having at least two valence electrons.
• the water buffer value is improved compared to an alkaline activation composition based on sulphates, hydroxides, carbonates, lactates, organophosphates or their combinations.
• the activation composition may comprise at least 40% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two valence electrons.
• the at least 40% by weight may correspond to several different metal oxides.
• the activation composition preferably when the latter is an alkaline activation composition, may comprise a single oxide of a metal having at least two valence electrons or more than 50% by weight of this metal oxide.
• the activation composition comprises at least 50% by weight of at least one metal oxide corresponding to the oxide of a metal, or of an alkaline earth, having at least two valence electrons, more preferably at least 60% by weight; even more preferably at least 80% by weight.
• metal oxides for example having at least two valence electrons
• XRF X-ray fluorescence spectrometry
• XRD X-ray diffraction
• the alkaline activating composition may comprise an organophosphorus compound such as sodium tripolyphosphate.
• the organophosphorus compound represents at least 2% by weight of the construction binder.
• the alkaline activating composition comprises a lactate such as sodium, potassium and/or lithium lactate.
• the activating composition can be a liquid composition.
• the activating composition can be an aqueous composition.
• its use can be combined with the addition of water during the formation of a construction binder according to the present invention.
• the activating composition is in solid form, for example in powder form.
• the indicated percentage of alkaline activating composition corresponds to the dry weight of the composition.
• the activating composition is for example present at a content of at least 2% by dry weight of the construction binder.
• the building binder comprises from 2% to 50% by dry weight of an alkaline activating composition. More preferably, the building binder comprises from 2% to 40% by dry weight of an alkaline activating composition. Even more preferably, the building binder comprises from 10% to 20% by dry weight of an alkaline activating composition.
• the concentration of alkaline activating composition required can vary widely depending on its composition.
• the construction binder according to the invention may comprise from 20% to 40% by weight of an alkaline activation composition. This is particularly the case when the alkaline activating composition comprises hydroxides.
• the construction binder according to the invention may comprise from 2% to 10% by weight of an alkaline activation composition. This is particularly the case when the alkaline activating composition comprises carbonates.
• the construction binder according to the invention may comprise from 10% to 30% by weight of an alkaline activating composition, preferably from 15% to 25% by weight of an activating composition.
• the presence of constituents of the activation composition can be identified by spectrometry methods which will depend on the activation composition used. For example, it will be possible to identify constituents of the composition in a construction material by infrared spectrometry.
• a construction binder according to the invention preferably comprises less than 15% by weight of Portland cement, more preferably less than 10% by weight, less than 8% by weight, less than 5 % by weight, less than 3% by weight, less than 2% by weight and even more preferably does not contain Portland cement.
• a composition of metal oxides advantageously comprises metal oxides selected from: iron oxides such as FeO, FesC, FesOs, alumina Al2O3, manganese(II) oxide MnO, titanium(IV) oxide TiOs , magnesium oxide MgO and mixtures thereof. It may also comprise metal oxides selected from: calcium oxides and magnesium oxides.
• a composition of metal oxides can also include aluminosilicates.
• composition of metal oxides is for example selected from:
• the metal oxides are transition metal oxides.
• the metal oxides can preferably come from a composition of blast furnace slags, for example formed during the production of cast iron from iron ore.
• the construction binder comprises at least 10% by weight of metal oxides.
• a construction binder according to the invention may comprise at least 15% by weight of a composition of blast furnace slags.
• the construction binder comprises for example 10% by weight of aluminosilicate, preferably at least 10% by weight, more preferably at least 20% by weight, resulting from a calcination process.
• the construction binder may comprise a composition of at least 20% by weight of calcined aluminosilicates or else the calcined metal oxide composition comprises aluminosilicates representing at least 20% by weight of the construction binder.
• Aluminosilicates come, for example, from alumina, red mud, fly ash, blast furnace slag or metakaolin.
• a balance between the amount of the calcined metal oxide composition and the raw clay matrix will, in combination with the alkaline activating composition, strengthen the bonds between the clay sheets so as to bring its mechanical properties to the binder while maintaining, thanks to the deflocculant and the type of clay selected, optimal hygrothermal properties.
• the clay matrix comprises smectite which the inventors have discovered to be particularly suitable, in combination with a deflocculation agent and an activating composition, for the preparation of construction materials having a high MBV value (eg >0.7, or preferably greater than 1).
• the inventors have identified that certain values of the ratio between the quantity by mass of composition of metal oxides and the quantity by mass of raw clay matrix allow an adequate balance between mechanical resistance, hygrometric capacity and speed of setting.
• the composition of metal oxides and the raw clay matrix are present in the construction binder so that a mass ratio of the raw clay matrix to the composition of metal oxides is less than or equal to 6, preferably less than or equal to 4, more preferably less than or equal to 2.
• the composition of metal oxides and the raw clay matrix are present in the construction binder so that a mass ratio of the raw clay matrix to the composition of metal oxides is preferably greater than or equal to 0 ,3; more preferably greater than or equal to 0.5 and even more preferably greater than or equal to 1.
• the composition of metal oxides and the raw clay matrix are present in the construction binder so that a mass ratio of the raw clay matrix to the composition of metal oxides is between 0.3 and 3 , more preferably comprised from 1 to 3, even more preferably comprised from 1 to 2.
• composition of metal oxides and the deflocculation agent are present in the construction binder so that a mass ratio of the composition of metal oxides to the deflocculation agent is greater than or equal to 12, preferably greater than or equal to 15.
• composition of metal oxides also called composition of calcined metal oxides
• the composition of metal oxides also called composition of calcined metal oxides, represents from 35% to 65% by weight of the construction binder.
• composition of metal oxides also called composition of calcined metal oxides, represents from 40% to 65% by weight of the construction binder.
• the presence of constituents of the calcined metal oxide composition can be identified by spectrometric methods which will depend on the calcined metal oxide composition used. For example, it will be possible to identify constituents of the calcined metal oxide composition in a construction material by scanning electron microscopy, by scanning electron microscopy coupled with a microprobe or by measurement by X-ray fluorescence spectrometry (XRF ) and/or by X-ray diffraction (XRD).
• the construction binder may comprise many other compounds. For example, it may comprise an adjuvant, preferably representing at least 1% by weight of said binder. In particular, the adjuvant is an air entrainer. The person skilled in the art can for example use those known in conventional concretes.
• blast furnace slag, fly ash or equivalent with raw clay, and an activating composition, preferably alkaline, to produce a building material with a good MBV (i.e. greater than or equal to 0.7) and capable of setting quickly.
• an activating composition preferably alkaline
• a clay matrix comprising at least one raw clay from the smectite family, the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder, and an activating composition, preferably alkaline, to produce a construction material having good water buffering capacity (MBV) and capable of exhibiting rapid setting.
• MBV water buffering capacity
• compositions or binders according to the invention which can be used effectively in a process according to the invention, the inventors have identified certain formulations of construction binder which are novel as such and which exhibit a reduced carbon balance, a rapid setting, hygrothermal properties and high mechanical performance. These novel and particularly effective formulations form part as such of the subject of the present invention.
• the invention also relates to a construction binder comprising a raw clay matrix, a deflocculation agent, a composition for activating said construction binder comprising:
• said raw clay matrix comprises at least one raw clay from the smectite family; and the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder; and less than 15% by weight Portland cement.
• the invention also relates to a construction binder comprising a raw clay matrix, a deflocculating agent, an activating composition, said construction binder comprising: - at least 40% by weight of raw clay matrix, said raw clay matrix comprises at least one raw clay from the smectite family; and the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder;
• the invention also relates to a construction binder comprising a raw clay matrix, a deflocculation agent, an activating composition, said construction binder comprising:
• said raw clay matrix comprises at least one raw clay from the smectite family; and the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder;
• deflocculation agent comprising an organic compound selected from: humates, lignosulphonate and polyacrylate.
• the invention also relates to a construction binder comprising a raw clay matrix, a deflocculation agent, an activating composition, said construction binder comprising:
• said raw clay matrix comprises at least one raw clay from the smectite family; and the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder;
• activating agent comprising at least 70% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two electrons of valence.
• the invention relates to a use, for the preparation of a construction binder, of a raw clay matrix comprising a mixture of at least two types of clay having a specific surface at least equal to 100 m 2 /g, in combination with a deflocculating agent and an activating composition.
• the raw clay matrix comprises at least one clay having a specific surface at least equal to 100 m 2 /g, a specific surface at least equal to 150 m 2 /g; a specific surface at least equal to 200 m 2 /g; or a specific surface at least equal to 250 m 2 /g.
• the raw clay matrix comprises at least two clays having a specific surface area at least equal to 100 m 2 /g, a specific surface area at least equal to 150 m 2 /g; a specific surface at least equal to 200 m 2 /g; or a specific surface at least equal to 250 m 2 /g.
• the invention also relates to a use, for the preparation of a building binder, of a raw clay matrix comprising at least one raw clay from the smectite family, the at least one raw clay from the smectite family represents at least 20% by weight of the building binder, in combination with a deflocculating agent and an activating composition; and the building binder comprising less than 15% by weight of Portland cement.
• the construction binder according to the invention can be used to produce covering elements, in particular floor coverings, such as tiles, slabs, cobblestones or curbs, wall coverings, such as interior or exterior facade elements , facing strips, cladding elements, or roof coverings of the tile type, for the production of extruded or molded building modules, such as bricks, or for the production of various extruded shapes.
• floor coverings such as tiles, slabs, cobblestones or curbs
• wall coverings such as interior or exterior facade elements , facing strips, cladding elements, or roof coverings of the tile type
• the construction binder according to the invention can be used for the production of composite materials, such as construction panels of the prefabricated panel type, prefabricated blocks such as door or window lintels, prefabricated wall elements, or any other prefabricated building element.
• the construction binder according to the invention can be used for the production of insulation modules, such as partition panels, or light insulating construction modules (with a density of less than 1.5 kg/L, preferably less to 1.2 kg/L, more preferably less than 1.0 kg/L, more preferably less than 0.7 kg/L).
• the invention also relates to the use of the construction binder according to the invention, for the implementation of additive manufacturing.
• the implementation of additive manufacturing can be carried out by means of an automated 3D construction system such as a 3D printer.
• Such additive manufacturing can allow the manufacture of construction elements, buildings or houses, or even decorative objects.
• the construction binder according to the invention can be used in the form of a two-component system with either on the one hand the constituents in solid form, and on the other hand the constituents in liquid form, or the constituents in the form of two pastes, for the realization of mastic, glue or sealing mortar.
• the invention relates to a process for the preparation of a construction binder. Such a process according to the invention relates in particular to the production of a building binder making it possible to generate building materials having high water buffering capacities (ie greater than 0.75).
• the raw clay matrix may comprise at least one mineral species selected from: Illite; Smectite preferably Montmorillonite; Kaolinite; Bentonite; Vermiculite; Chlorite; muscovite; Halloysite; Sepiolite or Attapulgite.
• Illite preferably Montmorillonite
• Kaolinite preferably Montmorillonite
• Bentonite preferably Vermiculite
• Chlorite muscovite
• Halloysite Sepiolite or Attapulgite.
• interstratified clays which are complex combinations of several clays.
• the method comprises in particular the mixture of a raw clay matrix, a deflocculation agent and an activating composition.
• the raw clay matrix comprises at least one raw clay from the smectite family and the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder.
• the building binder preferably comprises less than 15% by weight Portland cement.
• the process may include a step of homogenization, or mixing, so as to obtain a construction binder.
• This homogenization or mixing step can in particular last at least 45 seconds, preferably at least 60 seconds, more preferably at least 90 seconds; and for example less than 30 minutes; preferably less than 10 minutes; more preferably less than 5 minutes.
• the method according to the invention may include the addition of additives or materials making it possible to modify the mechanical properties of the final construction material.
• the materials added can for example be aggregates, whether recycled or not, chosen from fillers, powders, sand, gravel, gravel, and/or fibers, and optionally pigments.
• aggregates can correspond to sand or sand and other aggregates such as gravel, gravel, pebbles, hemp and/or other plant aggregates.
• the method may also include the addition of a plasticizer or a superplasticizer.
• the method may also include the addition of fibers.
• the fibers are, for example, selected from: plant fibers such as flax cotton, hemp, cellulose, bamboo, miscanthus fibers, synthetic fibers such as metal, glass, carbon, polypropylene and their mixtures.
• plant fibers such as flax cotton, hemp, cellulose, bamboo, miscanthus fibers
• synthetic fibers such as metal, glass, carbon, polypropylene and their mixtures.
• the presence of fibers can allow the formation of a building material with improved mechanical and insulating properties.
• the process may also include the addition of aggregates.
• the aggregates are for example selected from: gravel, crushed concrete, recycled and mixtures thereof.
• the method may also include the addition of an additive.
• the additive is for example selected from: a synthetic or natural rheological holding agent, an anti-shrinkage agent, a water-retaining agent, an air-entraining agent, a synthetic resin and mixtures thereof.
• the preparation of a construction binder according to the invention will include in particular the addition of sand and water.
• the sand may possibly come from cuttings, particularly in the case of “site” concrete.
• the sand can also be desert sand.
• the building materials obtained can for example be selected from: mortars, coatings, or plasters.
• the construction binder will be used for the preparation of prefabrication element.
• the invention relates to a method for producing a prefabricated element.
• it is important, in addition to the water buffering capacities, that the construction binder can allow rapid setting of the construction material.
• the prefabrication element is in particular prepared from a construction binder comprising a raw clay matrix, a deflocculation agent and an activation composition to which aggregates and water have been added.
• the raw clay matrix comprises at least one raw clay from the smectite family; the at least one raw clay from the smectite family represents at least 20% by weight of the construction binder; and the building binder comprises less than 15% by weight of Portland cement.
• the method benefits from the embodiments of the construction binder thus, more preferably the construction binder comprises less than 10% by weight of Portland cement, less than 8% by weight, less than 5% by weight, less than 3% by weight, less than 2% by weight and even more preferably does not contain Portland cement.
• a method 100 comprises the following steps: a step 110 of supplying a construction binder, a step 120 of mixing the constituents of the binder for construction material with the aggregates and the water, and a curing step 130 of the mixture.
• the method according to the invention can also comprise steps of preparing 101 molds, of unmolding 140 of the prefabrication element and of drying 150 of the prefabrication element.
• the inventors have determined selections of clays and conditions of use making it possible to obtain construction materials allowing high levels of mechanical resistance and rapid setting despite high levels of raw clay.
• the clay matrix may be present at more than 10% by weight of the binder for building material, preferably it is present at more than 20% by weight of the binder for building material.
• the raw clay matrix comprises at least one raw clay from the smectite family. It is when the raw clay matrix includes these clays (one or more) that the best results in terms of water buffering capacity are obtained.
• the inventors have determined that in order to obtain a construction material having a high water buffering capacity while exhibiting rapid setting, it is necessary to add a deflocculating agent and to carry out a heat treatment.
• the curing step 130 comprises a heat treatment of the mixture.
• the combination of carrying out a heat treatment and the presence of clays of the smectite family makes it possible to obtain a construction material having water buffering capacities greater than or equal to 0.75 while having a quick take.
• a method 100 for producing a prefabrication element according to the invention may include steps for preparing 101 molds, with for example the use of mold release agent and formwork oil, the use of shims for reinforcement, or even the use of systems allowing hermetic covering of parts or curing products.
• the method according to the invention may comprise a first step of preparing a mixture of construction binder.
• the step of preparing the construction binder mixture may, for example, include dry mixing. Indeed, a majority or all of the constituents of the construction binder can be used in dehydrated form.
• part of the constituents can be mixed dry while another part of the constituents is added in liquid form.
• the method according to the invention comprises a step 120 of mixing the constituents of the construction binder with aggregates and water.
• the water to dry matter mass ratio of the composition is preferably controlled.
• the water/dry matter ratio by mass is preferably less than 1, more preferably less than or equal to 0.6 and even more preferably less than or equal to 0.5. This ratio does not take into account the quantity of aggregates added.
• the aggregates may correspond to natural aggregates, artificial aggregates or even recycled aggregates.
• the aggregates may also include mineral aggregates, i.e. mainly made up of mineral matter and/or plant aggregates, i.e. mainly made up of material of plant origin.
• the aggregates may also include marine aggregates, i.e. mainly made up of organic or inorganic matter from the seabed such as siliceous aggregates and calcareous substances (e.g. ma ⁇ rl and shell sand).
• the mineral aggregates may, for example, correspond to sand, gravel, gravel, fillers (or fine materials), powders, fossilized waste and their combination.
• Plant aggregates may, for example, correspond to wood (chips or fibers), hemp, straw, hemp hemp, miscanthus, sunflower, cattail, corn, flax, rice husks, wheat bales, rapeseed, seaweed, bamboo, cellulose wadding, fiber cloth and their combination.
• a building material or a prefabricated element according to the invention when a building material or a prefabricated element according to the invention will comprise vegetable aggregates, it preferably comprises at least 10% by weight of vegetable aggregates, preferably at least 15% by weight of vegetable aggregates, so more preferably at least 20% by weight of vegetable aggregates, and even more preferably at least 25% by weight of vegetable aggregates.
• the construction material or prefabricated element according to the invention when plant aggregates are used, will comprise preferably at most 60% by weight of vegetable aggregates, and more preferably at most 50% by weight of vegetable aggregates.
• the construction material or prefabricated element according to the invention may preferably comprise between 10% and 50% by weight of plant aggregates and more preferably between 15% and 35% by weight of plant aggregates.
• plant aggregates in the compressed concrete block according to the invention they may be combined with mineral aggregates such as sand. This can improve the mechanical performance.
• Such a mixing step can advantageously but not limitatively be carried out in a device selected from: a mixer and a mixer truck or more generally within any device suitable for mixing a construction binder.
• a dispersion device using, for example, ultrasound can be used.
• the mixing step 120 can be carried out over a period of at most 24 hours, preferably at most 12 hours, more preferably at most 6 hours.
• it can be only several tens of minutes and therefore less than an hour or even a few tens of seconds.
• the mixtures can be made in the context of manufacturing on a press, vibrating or not, where the mixture is made a few seconds before the molds are filled.
• the method 100 according to the invention may include the addition of additives or materials making it possible to modify the mechanical properties of the final construction material.
• the method may also include the addition of a plasticizer or a superplasticizer.
• Process 100 may also include the addition of fibers.
• the fibers are, for example, selected from: plant fibers such as flax cotton, hemp, cellulose, bamboo, miscanthus fibers, synthetic fibers such as metal, glass, carbon, polypropylene and their mixtures.
• plant fibers such as flax cotton, hemp, cellulose, bamboo, miscanthus fibers
• synthetic fibers such as metal, glass, carbon, polypropylene and their mixtures.
• Process 100 may also include the addition of aggregates.
• the aggregates are for example selected from: gravel, crushed concrete, recycled and mixtures thereof.
• Process 100 may also include the addition of an additive.
• the additive is for example selected from: a synthetic or natural rheological maintenance agent, an anti- shrinkage, a water-retaining agent, an air-entraining agent, a synthetic resin and mixtures thereof.
• the method 100 according to the invention may also include a stage of curing 130 of the mixture.
• the curing step 130 is generally known to those skilled in the art who will be able to implement it. It can for example be carried out either by maintaining the products in hardening chambers, or by digging or even by spraying water or curing products.
• the curing step 130 preferably lasts at most 48 hours, preferably at most 24 hours, more preferably less than 23 hours and it can be substantially equal to 20 hours.
• the curing step 130 generally lasts at least two hours, preferably at least six hours and more preferably at least 12 hours.
• the curing step 130 is carried out in an airtight mold.
• the hermetic mold advantageously makes it possible to limit or eliminate the exchanges between the mixture and the outside air.
• the curing step may or may not include heat treatment. However, even in the case of the occurrence of a heat treatment, this is carried out at a temperature of less than 500°C thus, the clay is always raw after the cure and there is no elimination. bound water. In other words, the clay is not calcined and can still be considered raw clay.
• the effectiveness of the pozzolanic reaction on the mechanical properties of the concrete is not linked here to a total dehydroxylation and an amorphization of the clay contrary to what is observed during the use of metakaolin (Konan et al., Comparative study of dehydroxylation/amorphization in two kaolins of different crystallinity (J. Soc. cios-Afr. Chim. (2010) 030; 29 - 39).
• the reaction with the activating composition does not modify the structure of the raw clay which can always be identified in the final material by scanning electron microscopy for example.
• the heat treatment is carried out at a temperature above 25°C, preferably above 30°C.
• the curing step is carried out at a temperature below 120°C, preferably below 100°C and more preferably below or equal to 80°C.
• the heat cure step is carried out at a temperature between 20°C and 90°C, preferably the heat cure step is carried out at a temperature between 25°C and 80°C; even more preferably between 25°C and 65°C.
• the heat treatment can be carried out over the entire curing step but also over a shorter period.
• the heat treatment is carried out over a period of less than or equal to 20 hours, more preferably less than 15 hours, and even more preferably less than 10 hours.
• the method according to the invention may include a step 140 of stripping the prefabricated element.
• the mold release step 140 is generally known to those skilled in the art who will know how to set it up. This step is notably facilitated by any mold preparation steps, with, for example, the use of mold release agent and formwork oil, the use of shims for the reinforcement, or even the use of systems allowing hermetic covering of the parts.
• the method according to the invention may include a drying step 150 of the prefabrication element.
• the drying step 150 is generally known to those skilled in the art who will be able to implement it. This step can take place in special conditions, in particular sheltered from the wind, frost and the sun for example.
• the inventors have been able, for the first time, to obtain a prefabrication element or a construction material having a water buffer value greater than or equal to 0. .75, preferably greater than or equal to 01, more preferably greater than or equal to 1.2.
• certain prefabrication elements or a construction material are fast setting with a minimum resistance to compression on cylinders, after 20 hours or less of curing stage, as measured by standard NE EN 206-1 superior or equal to 16 MPa, preferably greater than or equal to 18 MPa, more preferably greater than or equal to 20 MPa.
• the construction binder is in particular a quick-setting construction binder and likewise, the construction material according to the invention is a quick-setting construction material.
• the methods according to the invention can incorporate the embodiments of the construction binder described above, whether or not they are advantageous, particular or preferred, in particular characteristics concerning the main constituents of the construction binder: the raw clay matrix, the deflocculating agent, the activating composition and the calcined metal oxide composition.
• the invention relates to a building material comprising a building binder according to the invention.
• the invention relates to a building material formed from a building binder according to the invention.
• the materials of construction can for example be selected from: a mortar, a coating, a plaster, an insulator, a lightweight concrete, a prefabrication element.
• the invention relates to a construction material obtained, or capable of being obtained, from a process according to the invention.
• the construction binder according to the invention is used to form a construction material so that the fillers represent between 200% and 900% by weight of the construction binder.
• the construction binder according to the invention preferably represents between 10% and 33% by weight of the construction material.
• a construction material formed from the construction binder according to the invention will comprise at least 5% by weight of raw clay from the smectite family.
• the construction material will comprise at least 8% by weight of raw clay from the smectite family and even more preferably at least 10% by weight of raw clay from the smectite family.
• a construction material formed from the construction binder according to the invention will also comprise at least 5% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two electrons of valence.
• the at least 5% by weight can be formed from several different metal oxides. These metal oxides may come from several sources.
• the metal oxides formed with a metal having at least two valence electrons will be contained in the activation composition and/or in the calcined metal oxide composition.
• the construction material comprises at least 10% by weight of at least one metal oxide corresponding to the oxide of a metal having at least two valence electrons, more preferably at least 15% by weight; even more preferably at least 20% by weight.
• the construction material according to the invention may comprise plant fibres, preferably shiv.
• the construction material according to the invention may comprise diatom frustules.
• the construction material according to the invention may have a water buffer value greater than or equal to 0.75; preferably greater than or equal to 1; more preferably greater than or equal to 1.2.
• the construction material according to the invention can have a minimum resistance to compression on cylinders at 1 day as measured by standard NF EN 206-1 superior or equal to 2 MPa; preferably greater than or equal to 3 MPa, preferably greater than or equal to 5 MPa.
• the building material according to the invention may have a minimum compressive strength on cylinders at 7 days as measured by standard NF EN 206-1 greater than or equal to 8 MPa, preferably greater than or equal to 10 MPa.
• the building material according to the invention may have a minimum compressive strength on cylinders at 28 days as measured by standard NF EN 206-1 of less than or equal to 40 MPa, for example less than or equal to 30 MPa. and preferably, as illustrated in the examples, less than or equal to 20 MPa.
• the minimum compressive strength on cylinders at 28 days may be much lower.
• the construction material according to the invention may have a minimum compressive strength on cylinders at 28 days as measured by standard NF EN 206-1 ranging from 10 to 30 MPa, preferably from 10 to 20 MPa. .
• the construction material according to the invention can be formed from a construction binder comprising excavated earth comprising the raw clay matrix.
• the construction binder according to the invention can be used for the manufacture of:
• binder according to the invention binder according to the invention and light aggregates of the “vegetable or porous” type;
• the construction binder according to the invention may for example comprise straw, rice husk, shiv, seaweed, wood chips, sunflower, sargassum, reed, wheat husks or other cereals and mixtures thereof;
• Fiber-reinforced concrete carbon fibers, glass, polyropylene, flax, hemp, yucca, jute, kenaf, ampelodesmos from Mauritania, coconut, oil palm, date palm, banana and pineapple..., high-temperature performance concrete,
• the invention also relates to the use of the construction binder according to the invention, for the production of composite materials or prefabricated blocks.
• the composite materials are, for example, construction panels of the prefabricated panel type, while the prefabricated blocks are, for example, door or window lintels, prefabricated wall elements, or any other prefabricated construction element.
• the invention relates to a prefabricated element capable of being formed from a construction binder according to the invention.
• this prefabricated element will have been formed from a construction binder according to the invention.
• this prefabricated element such as a partition, has a face with an area of at least 1 m 2 , more preferably of at least 1.5 m 2 , even more preferably of at least 2 m 2 .
• the prefabricated element may have a thickness of between 0.3 cm and 20 cm, advantageously between 0.5 cm and 10 cm and more preferably between 1 cm and 7 cm.
• a prefabricated element advantageously has a water buffer value greater than or equal to 0.75, preferably greater than or equal to 1, more preferably greater than or equal to 1.2 and even more preferably greater than or equal to 1, 5. This is particularly useful when the prefabricated element has a face with an area of at least 1 m 2 , more preferably at least 1.5 m 2 , even more preferably at least 2 m 2 .
• the invention is particularly suitable for such prefabricated elements when it comprises excavated clay soil.
• the construction binder according to the present invention is particularly suitable for a partition manufacturing process.
• a resistant construction material and having a fast setting time that is to say having a resistance to compression of at least 2 MPa after 24 hours and greater than 10 MPa after 28 days and which, once dry, has an MBV greater than 0.8, preferably greater than 1.2 and for example between 0.8 and 3.
• the present invention relates to a use of a building binder according to the present invention for the manufacture of partitions, preferably prefabricated partitions and even more preferably partitions having a compressive strength of at least 2 MPa after 24 hours and greater than 10 MPa after 28 days and which, once dry, has an MBV of between 0.8 and 3.
• a use may include the addition to the construction binder according to the invention of fillers such as: sand, plant fibers such as chènevotte.
• the construction binder according to the invention is used so that the fillers represent between 200% and 900% by weight of the construction binder.
• the construction binder according to the invention preferably represents between 10% and 33% by weight of the construction material.
• the invention also relates to a partition prepared from a construction binder according to the invention.
• a partition may include other biobased materials.
• a construction binder according to the present invention when used for the manufacture of an insulating construction material, it may comprise light aggregates of plant origin.
• the present invention also relates to a construction binder comprising a raw clay matrix, a deflocculating agent and an activating composition, characterized in that it has a minimum resistance to compression on cylinders as measured by the standard NE EN 206-1, at 28 days greater than or equal to 12 MPa, preferably greater than 15 MPa and a water buffer value greater than or equal to 0.7, preferably greater than or equal to 1, more preferably greater or equal to 1.2 and even more preferably greater than or equal to 1.5.
• the construction binder will also comprise a composition of calcined metal oxides.
• the present invention relates to a building binder comprising a raw clay matrix, a deflocculation agent and an activating composition, the building binder allowing the preparation of a building material having a minimum resistance to compression on cylinders as measured by standard NF EN 206-1, at 28 days greater than or equal to 12 MPa, preferably greater than 15 MPa and a water buffer value greater than or equal to 0.7, preferably greater than or equal to 1 , more preferably greater than or equal to 1.2 and even more preferably greater than or equal to 1.5 measured no earlier than 10 days after manufacture and preferably 28 days.
• the construction binder will also comprise a composition of calcined metal oxides.
• the invention may also relate to a construction binder comprising a raw clay matrix, a deflocculation agent and an activating composition, the clay matrix raw material comprising a mixture of at least two types of clay, preferably the clay matrix comprising at least smectite. More preferably, the two types of clay have a specific surface at least equal to 30 m 2 /g, preferably at least equal to 50 m 2 /g, more preferably greater than 100 m 2 /g.
• the invention relates to a construction binder comprising a raw clay matrix, a deflocculation agent, and an activating composition, characterized in that the raw clay matrix comprises a mixture of at least two types clays, for example including smectite, and in that the binder further comprises a composition of calcined metal oxides.
• the calcined metal oxide composition is a blast furnace slag.
• the construction binder comprises at least 20% by weight of calcined metal oxide composition, more preferably at least 20% by weight of blast furnace slag.
• the invention also relates to a construction binder comprising a green clay matrix, a deflocculation agent, an activating composition and a calcined metal oxide composition, characterized in that the deflocculation agent comprises a lignosulphonate, a polyacrylate , a humate or a mixture thereof.
• the invention also relates to a building binder comprising a raw clay matrix, a deflocculating agent, an activating composition and a calcined metal oxide composition, characterized in that it comprises from 30% to 70% by weight , preferably from 40% to 60% by weight of raw clay matrix and in that it has:
• calcined metal oxide composition being a slag from metallurgy, such as a blast furnace slag.
• the invention also relates to a construction binder comprising a raw clay matrix, a deflocculation agent, an activating composition and a composition of calcined metal oxides, characterized in that it comprises:
• the present invention provides a solution based on a mixture of raw clay matrix, deflocculating agent and activating composition to provide a construction binder with mechanical properties similar to the standard while with a reduced carbon footprint.
• the formulations according to the invention are prepared according to an identical protocol, namely that a dry premix is carried out between a raw clay matrix, a deflocculating agent and the activating composition in quantities predetermined values, then water is added and the solution is mixed at low speed, that is to say substantially at sixty revolutions per minute for thirty seconds. Next, sand is added to the premix and the whole thing is mixed at a higher speed, i.e. at about 120 rpm for one minute.
• the water to dry matter mass ratio of the composition (also called construction binder) is adjusted to a value of between 0.4 and 0.6.
• the construction material comprises 25% by weight of binder, 75% by weight of sand; this mixture being supplemented with water for a mass ratio of water to dry matter of the binder adjusted to a value of 0.5.
• the mortar based on the building binder thus formed is then poured into a mold and left to mature at room temperature, that is to say around 20 degrees Celsius for twenty-eight days.
• the mortar can be poured into a mold and then left to mature for less than twenty-four hours in a curing step, at room temperature, i.e. around 25 degrees Celsius or preferably under heat treatment.
• the mold can be sealed or the top layer of building material can be covered with a curing compound to limit/prevent evaporation.
• mechanical strength of a construction binder means its resistance to compression, such compression being measured according to standard NF EN 196-1, for a prism of 40 millimeters side and 160 millimeters in length and is expressed in Mega Pascal (MPa).
• the water buffer value can be measured by any method known to those skilled in the art.
• the person skilled in the art may refer to the method described in “Durability and hygroscopic behavior of biopolymer stabilized earthen construction materials” Construction and Building Materials 259 (2020).
• the samples are placed in a climatic chamber at 23° C. and 33% relative humidity and are left until they have a constant mass (for example a climatic chamber model MHE 612). All samples equilibrate after 15 days of storage under these conditions.
• the samples are then exposed to cycles of high humidity (75% RH for 8 h) then a cycle of low relative humidity (33% RH for 16 h).
• the samples are weighed at regular intervals with a laboratory balance accurate to 0.01 g. After two stable cycles, the samples left the climatic chamber.
• MV where Am is the change in mass of the sample due to the change in relative humidity, S is the total exposure area, and A% RH is the difference between the humidity levels.
• Table 2 presents, for different types of construction binders, known formulations and a formulation according to the invention.
• the mass of the components relating to each formulation is expressed as a percentage of the total mass of the building binder (dry weight).
• MUP1 comprising 20% by weight of Smectite has an MBV greater than 0.75 (0.88)
• MUP0 comprising 10% by weight of smectite and 10% by weight of kaolinite has an MBV below the limit of 0.75.
• MUP-Y0 comprising approximately 40% kaolinite does not allow an MBV value greater than or equal to 0.75 to be reached
• MUP-Y1 comprising approximately 40% smectite allows an MBV value of 1.4 to be reached.
• clays of the smectite family are very advantageous for the preparation of building materials with water buffering capacities capable of improving the comfort of the inhabitants by thermal and water regulation.
• MUP-Y2 a mixture of clay
• MUP-Y2 a 50/50 mixture of Smectite and Kaolinite
• Table 3 presents a known formulation of Cement CEM1 -X1 to which a deflocculating agent has been added and five cement formulations to which clay has been added CEM1 -X2, CEM1 -X3, CEM1 -X4 and CEM1 - X5, in different proportions. [Table 3]
• CEM1-X1 achieves very high mechanical strength but has an insufficient MBV ( ⁇ 0.75).
• Table 4 below presents a reference formulation MUPZ0, a formulation according to the invention MUPZ1 and a formulation according to the invention MUPZ2.
• Table 2 shows that the replacement of Portland cement by an activation composition and a composition of calcined metal oxides (eg of the blast furnace slag type or ashes) allows for the MUPZ1 and MUPZ2 compositions to achieve much higher MBVs at 0.75.
• a composition of calcined metal oxides eg of the blast furnace slag type or ashes
• the MUPZ2 composition which includes an organic deflocculant, has an MBV almost equal to 2 while having a compressive strength greater than 25 MPa.

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• 2022
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