ES2277776A1 - Plaster mixtures for producing construction elements, contain expanded spherical plastic granules - Google Patents

Abstract

Expanded spherical plastic granules with a given diameter are combined with plaster or gypsum. Two mixtures of gypsum or plaster with expanded spherical plastic granules having a diameter of ca. 6 mm are described. These mixtures are combined with water and additives to produce construction elements. A first mixture is prepared by mixing a quick-setting or E-35 plaster with 80 wt.% water (with respect to dry plaster) for 1 minute, adding 1.6 wt.% plastic granules and continuing mixing for 3-4 minutes. A second mixture is prepared by mixing E-35 plaster with 200 wt.% water for 2 minutes, adding 8.1 wt.% plastic granules and continuing mixing for 5 minutes.

Description

Mixtures of plaster or plaster lightened with expanded plastic granules.

The invention relates to two formulations of mixtures of plaster or plaster and granules of expanded plastic and Your procurement processes The formulation of low percentage of expanded plastic, and formulation panel with higher percentage of expanded plastic. It corresponds to the areas of The technique of: building materials, expanded plastics and Recycled materials

State of the art

The expanded plastic is a plastic material rigid cell phone manufactured from plastic pearl molding expandable presenting a closed cell structure filled normally of air. An expanded plastic is also a plastic cellular and whose apparent density has decreased substantially by the presence of numerous cells arranged within its mass. Expanded plastics are two phase systems solid-gas that form a body similar to a sphere in which the solid is continuous and composed of a polymer synthetic or rubber than where their cells are discrete and their phase soda is independent of other cells, that is to say it is a "closed cell" material.

Although there are various plastics expanded in the The best known market of these is expanded polystyrene, internationally known by the acronym: EPS.

To obtain expandable polystyrene is performed a radical polymerization in water suspension. To the monomer of styrene is added before or during polymerization a low boiling benzine fraction, which is composed mainly of n-pentane and of iso-pentane as expanding agents. These are consider the typical agents present in the reaction, although other low molecular weight hydrocarbons are also used with chains between 3 and 6 carbon atoms such as butane, isobutane, Neopentane, hexane and mixtures thereof. The reaction occurs in stainless steel reactors mechanically agitated and with temperatures controlled by shirts cooling-heating The result of the process Above is the raw material of EPS which are small pearls of polystyrene containing the same agents inside expansion. Pearls are spheres with diameters ranging from 0.2 to 3 millimeters EPS granules ready to be converted into products are transformed into blocks, plates and objects molded

The use of expanded polystyrene has been made common in applications such as construction and packaging. In the construction its uses are generally thermal insulation and acoustic, of aids for the molding of construction elements and in civil engineering works such as land leveling and in the preparation of embankments. In the area of container and packaging it is used for example for applications of: food transport, protection of household appliances, computer equipment, handling agricultural products, etc.

The great diversity of EPS applications is due to its low density properties that allow to offer compact and very light products with a density range ranging from 10 to 50 k / m 3. The expanded polystyrene shows a remarkable ability to insulate heat or cold and noise, characteristic that is due to air or gas occluded within a plastic cellular structure, where approximately 98% of the spherical body is air and the rest is plastic material. The EPS thermal conductivity ranges from 0.046 W / mK for low density (10 k / m3), up to 0.033 W / mK for high density (35 k / m 3). The EPS is also a stable plastic against attack of many common chemicals like saline solutions and Diluted acids, it is also resistant to biological attack.

There are also EPS milled on the market that they come from the recovery of packaging and packaging waste from that material. These wastes are used as lightening materials of construction such as cement based binders, in the plaster, or the plaster.

Plaster or plaster are complex systems where through the partial or total dehydration of sulfate calcium dihydrate (SO 4 2H 2 O) semihydrates are obtained alpha or beta and anhydrides with various forms. Of the formulation of these materials are obtained construction plasters and plaster The application of plaster in construction is very ancient, currently to masonry uses that traditionally have been given to plaster or plaster can be added manufacturing of preconstructed elements, for the manufacture of partitions, for roof plates and complements and plate production laminates for partitions and wall coverings in interiors

The main novelty of this invention is the use of ground EPS waste, or in general granules of expanded plastics, such as additions or loads of a plaster matrix or plaster to manufacture materials useful in the construction of buildings, in two concrete formulations in which also Explains the procedure for obtaining. There is a history of application of cellular materials as lightening aggregates of a matrix obtained from a hydraulic binder. Like that of a patented product consisting of a concrete mixed with pearls of expanded polystyrene. Another antecedent is that of materials consisting of a lightened plaster matrix with ground cork, or with the possible incorporation of tree pruning waste, or waste of cork, or of pearls of EPS, (ES 2 170 612 A1). Too materials formed with a sponge cement matrix are known with aggregates of EPS granules and waste granules of EPS.

Explanation of the invention.

The invention consists of two mixtures with which you get a cast or lightened plaster useful for manufacture of large format construction elements such as: 1) A lightened plate, with uses similar to those given to the standard laminated plate on the market consisting of a core of plaster or plaster framed with cardboard coating or paper on both sides and used to manufacture partitions interiors or wall cladding or roof manufacturing or ceilings; and 2) A thermal insulation panel, with uses similar to those given to the existing EPS panel in the market.

The materials that constitute the plate lightened are the thin plaster or plaster binder added with setting accelerating additives, with a ratio of water-plaster of approximately 80%, and a load of lightening expanded plastic granules with a relationship Approximately 1.6% of the weight of the dry binder. Coulding be these expanded polystyrene granules, expanded polyethylene, expanded polypropylene or other expanded plastics.

The plates obtained with this material they offer mechanical resistance properties that tend to those of standard laminated plates improving insulation thermal offer the materials available in the market as well They are approximately 23% lighter than the latter. By on the other hand its reaction to fire is otherwise attractive already that despite containing plastic material is a low material combustibility that does not deposit burning drops or produce fumes, These latter features allow its use inside buildings.

The materials that constitute the panels of thermal insulation are plaster or preferably plaster that It comes from plaster stone with high purity and fineness added with setting additives, with a water-plaster ratio approximately 200% of the weight of the dry binder and a 8.1% expanded plastic lightening load about the weight of the dry binder.

The panels obtained with this material offer compressive and flexural strength properties better than those offered by some insulating panels expanded plastic only as EPS although they have a density higher. The thermal conductivity of a plate manufactured with the Proposed material (0.065 W / mK) tends to that of a standard product which is widely used in construction as a thermal insulator such as EPS panels with the advantage for materials proposed, that its fire reaction characteristics allow place it only with a thin or non-plastered plaster, which is necessary in EPS panels.

In both mixtures it is also allowed to add additives in order to improve the workability of the mixture as they are superfluidifying and setting regulators as well as reinforcements of mineral or organic origins. Also allowed improve the mechanical performance of the plates through the coating with cardboard or thin papers on the face and the back of the core of lightened plaster.

Thus, the percentages of the components of the mixture used to make lightened plates are: Fine plaster of 100% fast setting, 80% water binder weight, granules of plastic expanded by approximately 1.6% by weight of binder.

For the preparation of the plate mixture the fine quick-setting plaster must be kneaded for 1 minute with water in a proportion of 80% of the weight of the dry binder to then add the expanded plastic granules in a proportion 1.6% by weight of dry binder, continuing kneading for 3 or 4 minutes.

The percentages of the components of the mixture Used to manufacture thermal insulation panels are: Plaster (E-30 or E-35) to obtain prefabricated, water 200% by weight of the binder, granules of expanded plastic approximately 8.1% by weight of binder.

For the preparation of the panel mix the plaster has to be kneaded for 2 minutes with water in a proportion of 200% of the weight of the dry binder for later add the expanded plastic granules in a proportion of the Approximately 8.1% by weight of dry binder, continuing the Kneading for 5 minutes.

Behavior of the mixtures

Plasterboard and plasterboard lightened with expanded plastic granules are materials that they meet the characteristics to be building materials with excellent performance, which highlights the ease of production of  the same and the wide availability of the necessary raw material for its manufacture:

Plasterboard lightened with granules of plastic has a total immersion water absorption of 56.1% while the standard plate has a slightly lower absorption (54.7%) although the loss of absorbed liquid is much faster in the composite material and with it the recovery of some of His properties. Material density plaster-plastic granules is 23% lower than the standard material and the flexural strength of the material compound (234 N) tends to be similar to that of the plate now commercially available (approximately 273 N) although its Impact resistance is lower. The reaction to fire of lightened materials are similar without exceeding plates standard.

Lightened drywall with granules of plastic show greater resistance to bending and compression than similar insulation materials such as panel  of EPS. The thermal conductivity of the proposed panel (0.065 W / mK) is greater than the common plastic insulators in construction, however it is better than some other insulating materials Traditional An attractive feature for building plaster materials-plastic granules expanded as described here, is its reaction to fire where shows behaviors that surpass plastic materials similar to those shown in the EPS, the composite material tends to be a material that does not promote combustion, which does not produce fumes or burning particles.

Both the plates and the panels described economize raw materials and solve a management problem of waste using ground waste from EPS.

Brief description of the drawings

Figure 1 represents a cross section without being in scale, of a plaster binder plate or plaster with expanded plastic granules. A cardboard is drawn or paper that covers the back of the plate (1), some plastic granules expanded conglomerates (2), the body of set plaster (3) that contains in its mass the expanded plastic granules and by last a layer of cardboard or paper that covers the face of the plate and wrap your sides (4).

Figure 2 represents a cross section without being in scale, of a plasterboard panel or plaster with a higher proportion of plastic granules expanded than in the case of the plate in figure 1. A drawing is drawn cardboard or paper covering the back of the panel (1), some granules of expanded plastic conglomerates (2), and the body of set plaster (3) containing in its mass the plastic granules expanded.

Detailed presentation of an embodiment

Without being limiting, they are exposed to below a specific embodiment of the present invention, where obtaining the plates and panels for the construction requires as a first step the manufacture of the material composed of plaster or plaster and expanded plastic granules, and then the other elements that compose it:

Quick-setting fine gypsum boards with expanded plastic granules with measures similar to those of the standard laminated plate that from 2600 x 600 mm with thicknesses variable from 12.5 mm (and after 15 and 18 mm). Plates are wrapped in his face and long sides by a canvas of thick paper or cardboard of at least 0.4 mm. On the back of the plate place a paper or cardboard canvas of at least 0.4 mm.

Plaster panels for prefabricated with expanded plastic granules with measures similar to those of EPS panels only from 2200 x 600 mm with a thickness variable from 30 mm.

Manufacture of the mixture for lightened plasterboard

For the preparation of the plate mixture the fine quick-setting plaster to be kneaded in a container provided with shake blades for 1 minute with water 23 (± 2) ° C at a rate of 80% of the weight of the Dry binder to then add the plastic granules expanded from EPS waste that has been previously ground, in a proportion of 1.6% by weight of dry binder, continuing kneading for 3 or 4 minutes. Then the dough is deposited on paper or cardboard that will shape the face of the plate, and a canvas of paper attached to the back is attached pieces of face paper protruding from the sides Longitudinal of the plate.

Mix manufacturing for lightened drywall

For the preparation of the panel mix the plaster must be kneaded for 2 minutes with water to 23 (± 2) ° C in a proportion of 200% of the weight on Dry binder, then add the plastic granules expanded from EPS waste that has been previously ground, in an approximate proportion of 8.1% by weight of Dry binder, continuing kneading for 5 minutes. Then the dough is deposited on the paper or cardboard that will form the panel face.

Claims (10)

1. Mixes of lightened plaster or plaster with expanded plastic granules, consisting of plaster or plaster materials, regulatory additives, reinforcements of mineral or organic origin, and particles of expanded or foamed plastic material, characterized in that the addition of such materials allows form plates for the construction of use similar to those of standard laminated plaster, by adding to the plaster or plaster binder, a load of expanded plastic granules in an approximate proportion of 1.6% by weight of the dry binder, and also allows forming a panel similar to insulating panels, when adding to the plaster or plaster binder, a load of expanded plastic granules in an approximate proportion of 8.1% by weight of the dry binder. 2. Plaster or plaster mixtures lightened with expanded plastic granules according to claim 1, characterized in that said plates are prepared with a water share of approximately 80% by weight of the binder and for said panels they are prepared with a participation of water of the Approximately 200% by weight of the binder. 3. Blends of plaster or plaster lightened with expanded plastic granules according to claim 1, characterized in that they incorporate additives, such as superfluidifiers or setting regulators, or reinforcements of mineral or organic origin. 4. Blends of lightened plaster or plaster with expanded plastic granules according to claim 1, characterized in that they can incorporate paper or cardboard on one or more of their faces. 5. Mixes of lightened plaster or plaster with expanded plastic granules according to claim 1, characterized in that the expanded plastic granules are made of ground EPS waste. 6. Lightened plaster or plaster mixtures with expanded plastic granules according to claim 1, characterized in that the expanded plastic granules resemble spheres of approximately 6 millimeters in diameter. 7. Plaster or plaster mixtures lightened with expanded plastic granules according to claim 1, characterized in that the process of making said plates is based on kneading the binder with water at temperature at 23 (± 2) ° C for 1 minute, with subsequent addition of expanded and kneaded plastic for 3 or 4 more minutes. 8. Plaster or plaster mixtures lightened with expanded plastic granules according to claim 1, characterized in that the process of manufacturing said panels is based on kneading the binder with water at temperature at 23 (± 2) ° C for 2 minutes, with subsequent addition of expanded and kneaded plastic for 5 more minutes. 9. Lightened plaster or plaster mixtures with expanded plastic granules according to claim 1, characterized in that said plates can be used for the construction of partitions and interior wall coverings, with typical measures 600 mm wide by 2600 mm long and with variable thicknesses of 12.5, 15 and 18 mm. 10. Lightened plaster or plaster mixtures with expanded plastic granules according to claim 1, characterized in that said panels can be used for the construction of thermal insulation coatings of interior walls and to be applied in empty chambers between walls, with typical measures of 600 mm wide by 2200 mm long and with a variable thickness from 30 mm.