ES2402454A1 - Fluid conglomerant, method of obtaining and its use as a covering of metallic construction elements. (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

The present invention relates to a binder with fire-retardant properties comprising gray cement in a percentage comprised between 60% and 64%, vermiculite between 35% and 37%, bentonite between 0.97% and 1.03% and redispersible binder based on of a copolymer of vinyl acetate and vinyl versatate (veova) between 0.97% and 1.03%, including both limits, of the total weight of the composition of the binder. Likewise, another object of the present invention is a fire-retardant mortar obtainable from the binder composition and water, as well as the method of manufacturing the composition, by adding the components and mixing. The present invention also relates to the use of the binder composition for manufacturing a flame-retardant mortar, and the use thereof to coat constructive elements, such as in particular metallic structures. (Machine-translation by Google Translate, not legally binding)

Description

Flame retardant binder, method of obtaining and its use as a coating of metallic construction elements

SECTOR OF THE TECHNIQUE

The present invention refers to the manufacture and application of compositions with cement-based and flame-retardant properties and of the fire-retardant mortars obtainable from said compositions, specially designed for coating and fire protection of metal structures, such as They are commonly used in industrial plants such as refineries, petrochemicals, etc. in which fire curves called hydrocarbons are used for the calculation of protection. Therefore, said invention is encompassed in the field of construction, specifically in the area of cementation.

STATE OF THE TECHNIQUE

The manufacturing process of this type of mortars or binder compositions with fire retardant properties consists of mixing cement and light materials such as vermiculite or perlite, adding special additives depending on the technical characteristics required for the protection of building elements against Fire and high temperatures, especially of metallic elements. Two examples of this type of binder and fire retardant mortar compositions are those described in Spanish patent application ES513917, relating to a fire retardant mortar based on dehydrated calcium sulfate and inert fine particles, and in patent ES 2170662, which describes a Chemical composition for use as a fire retardant mortar based on vulcanized rubber, catalyst and a fire retardant chemical, which is mixed with a polymeric resin aqueous emulsion and packaged in an inert atmosphere to prevent hardening of the mortar.

Said products, once mixed with water to obtain a fire retardant mortar and applied on the metal structure to be coated, become a protection around said metal structure capable of withstanding aggressive environments against fire and allowing non-collapse of it.

Faced with the complexity of fire protection actions in metal structures in industrial plants, this mortar achieves better malleability for application as well as better adhesion to the support, compared to other mortars already known in the field such as above

DESCRIPTION OF THE INVENTION

The main object of the present invention is a binder composition with flame retardant properties, also called "flame retardant binder" throughout the present specification, which comprises:

-

gray cement, in a percentage between 60% and 64% of the total weight of the binder, including both limits;

-

vermiculite, in a percentage between 35% and 37% of the total weight of the binder, including both limits;

-

bentonite, in a percentage between 0.97% and 1.03% of the total weight of the binder, including both limits; Y

-

at least one redispersible binder based on a copolymer of vinyl acetate and vinyl versatate (veova), in a percentage between 0.97% and 1.03% of the total weight of the binder, including both limits.

The sum of these components is less than 100% by total weight of the binder composition, that is, their combination never reaches that value. This allows the optional addition of other common components in the field.

In a preferable embodiment of the invention, the flame retardant binder consists of the following composition:

-

gray cement, in a percentage between 60% and 64% of the total weight of the binder, including both limits;

-

vermiculite, in a percentage between 35% and 37% of the total weight of the binder, including both limits;

-

bentonite, in a percentage between 0.97% and 1.03% of the total weight of the binder, including both limits; Y

-

at least one redispersible binder based on a copolymer of vinyl acetate and vinyl versatate (veova), in a percentage between 0.97% and 1.03% of the total weight of the binder, including both limits,

the sum of these components being equal to 100% by total weight of the binder composition, that is, any combination of the components that could exceed said value is excluded, for consistency. In an even more particular embodiment of the invention, the fire retardant cement binder specifically presents the following formulation: gray cement in 62%; -vermiculite in 36%; -bentonite in 1%; and -a redispersible binder based on a copolymer of vinyl acetate and vinyl versatate in 1%. Preferably, the gray cement (also called in the Portland cement field) is sulfatresistant gray cement, more preferably CEM I 52.5 N / SR type gray cement. Also preferably, the vermiculite is expanded vermiculite grade 2 (referred to herein as vermiculite-G2). Also, bentonite is preferably standard sodium bentonite. In a very particular and preferred embodiment of the present invention, the fire retardant cement binder has the following formulation: - CEM I 52.5 N / SR gray cement in 62%; -vermiculite G2 in 36%; - 1% standard sodium bentonite; and -a redispersible binder based on a copolymer of vinyl acetate and vinyl versatate in 1%.

Within the scope of the present invention, CEM I 52.5 N / SR cement is a type of gray cement or Portland type sulfate-resistant cement, which has the following characteristics (UNE EN 197 1: 2000 specifications):

· Clinker (%) 95-100 · Limestone (L) (%) 4 · Setting regulator, “gypsum” (%) 6 · Sulfur trioxide (SO2) (%) <4 Chlorides (Cl) (%) <0 , 1 Loss on calcination (%) <5 Insoluble residue (%) <5

For its part, within the scope of the present invention, vermiculite-G2 has the following characteristics: · Density 2.6

PH

6 - 8

Specific heat (Kj / KgK)

one

· Retention capacity

  of water (% dry weight)

240

· Exchange capacity

of cations (m-eq / 100g)

90 - 100

3

Thermal conductivity (W / mºC) 0.062 - 0.065

  Granulometry (% by weight) of Grade 2:

>> 3.15 mm <10%

1 - 3.15 mm> 60%

<0.25 mm <5%

As for the standard sodium bentonite, within the scope of the present invention it presents the following

features:

White beige powder appearance

Humidity <16%

· Granulometry:

 +100 ASTM <5%

100/200 ASTM <50%

Inflammability> 25ml / 2g

Specific weight 2.6 g / cm3 approx.

Apparent density 0.5 - 0.6 g / cm3

With regard to the redispersible binder of the copolymer of vinyl acetate and vinyl versatate (veova), within the scope of the present invention it has the following characteristics: · White powder free flow aspect · Apparent density 400 to 600 g / l · Residual humidity <2% · Ashes (DIN EN 1246/950 ° C, 30 min) 10.0% +/- 2.0% · pH value 7.0 to 9.0 (in a 10% dispersion in water) · Min. Film formation approx. 0 ° C · Properties of the opaque, viscoplastic film The main mission of each of the components in the described binder is as follows:

-

 Cement is the main component that brings together all the other components of the mortar (matrix); It is a mixture of limestone and clay materials composed mainly of calcium silicates, mainly responsible for hardening, and other elements such as tricalcium aluminate and tetracalcium aluminate ferrite, necessary to reduce the formation temperature of calcium silicates, as well as small portions of other oxides (MgO, SO3, Na2O, K2O) from raw materials or fuel. It is primarily responsible for mechanical resistance, resistance to temperature changes, resistance to chemical attacks, etc.

-

 Vermiculite is a mineral from the Mica family, composed of aluminum, magnesium and iron silicates. In the present composition, its function is to improve thermal conductivity while decreasing the density of the product to avoid overloading the structure.

-

 Bentonite is a fine-grained clay that confers plasticity to the mixture and improves the agglutination of all components.

-

 The redispersible binder based on the copolymer of vinyl acetate and vinyl versatate (veova) has as its main mission to improve the adhesion of the finished product to the original substrate and improve its abrasion resistance.

A second aspect of the present invention is the cement-based fire retardant mortar obtainable from the binder described above, in any of its variants, and water. In the scope of the present specification, "flame retardant mortar" is understood as a binder composition that is usually mixed with water and which may also comprise additional additives, and which, thanks to the properties conferred by the components of said binder, has fire retardant properties. once applied on the surface of the structure to be coated.

Preferably, the binder is mixed with water in the following proportion: between 0.9 and 1.35 liters of water per Kg of fire retardant binder, including both limits. This mixture gives the mortar the optimum of the technical characteristics mentioned above for each of its components. Therefore, the main advantages obtained with this mixture that configures the fire retardant mortar are the best plasticity of the same, which confers a better handling, better adhesion to the substrate of origin and a substantial improvement in the appearance of cracks by retraction once applied.

It should be taken into account in the scope of the present invention that the described fire retardant mortar, in any of its variants and alternatives, may in turn contain another or other additional additives commonly used in the field, such as setting accelerators, braiding fibers or any other element that in a small proportion (slightly, without affecting its advantageous properties) modifies / improves the mechanical or physical properties of the mortar.

The fire retardant mortar described, in any of its variants, can be used to cover structures, walls, or any other constructive element that has to increase its resistance or stability to fire. In a particularly preferred case, the mortar is used to coat and protect metal structures, which is where the best results have been proven.

A third aspect of the present invention is a method of manufacturing the flame retardant binder protected herein, in any of its variants, which comprises adding all the components at once and subjecting them to mixing until they are completely homogenized. Preferably, the mixing of the components is carried out by silo automation. Also preferably, all the components of the binder are added at once in a weighing hopper in the corresponding proportions, of which in turn they are preferably transferred to a rotating drum for mixing. In a preferred embodiment, the mixing of the components is carried out for a time ranging from 8 to 10 minutes, including both limits, ensuring the proportion of elements in each manufacture.

Once the mixing process is finished, the prepared binder is ready for use, or to be packaged if desired, for example in sacks; It can be optionally transported by buckets to a bagging hopper, which by weighing bags the finished product in bags for later handling on site.

After preparation, regardless of whether it is packaged for later use or if used directly, the binder can be mixed with water to make a fire retardant mortar. The proportions of binder and water preferred are those discussed above to refer to the mortar.

The fire retardant mortar can be applied to the structure or construction element by spraying using a conventional device for this purpose, and using a reinforcement, such as a mesh, which is fixed to the structure to be coated.

DESCRIPTION OF THE FIGURES

Figure 1. Formwork arrangement for application of the fire retardant mortar object of the present invention as a cube-shaped coating of a metal column. Top view of the column (1) and the arrangement of the formwork (2) around it to apply the mortar.

Figure 2. Alternative formwork arrangement for application of the fire retardant mortar object of the present invention as a coating of a metal column. Cladding in the form of a column profile. Top view of the column (1) and the arrangement of the formwork (2) around it to apply the mortar, also including partial formwork (3) in the column profile so that the coating maintains, once applied, said profile.

Figure 3. Cube-shaped coating of a metal column by means of the fire retardant mortar object of the present invention according to Figure 1. General perspective view of a metal column (1) coated by the fire retardant mortar (4), using a reinforcement mesh (5). Corresponds to the formwork arrangement shown in Figure 1.

Figure 4. Alternative coating of a metal column by means of the fire retardant mortar object of the present invention, according to Figure 2. General perspective view of a metal column (1) covered by the fire retardant mortar (4) using a reinforcing mesh (5), said mortar maintaining the profile of the column.

EXAMPLES OF EMBODIMENT OF THE INVENTION

Example 1. Preparation of a fire retardant binder and a fire retardant mortar in accordance with the present invention.

The components of the binder are mixed by silo automation, as follows: all components are added at once in a weighing hopper in the following proportions:

-

CEM I 52.5 N / SR gray cement in 62%;

-

grade 2 vermiculite (G2) by 36%;

-

1% standard sodium bentonite; Y

-

Redispersible binder based on copolymer of vinyl acetate and vinyl versatate in 1%.

Once weighed, they are transferred to a rotating drum in which they are mixed for a time between 8 and 10 minutes. Once the mixing process is finished, the powder prepared binder is transported by buckets to a bagging hopper, which by weighing bags the finished product into bags for subsequent handling on site.

Subsequently, the fire retardant binder is mixed with water, in the following proportion: between 0.9 and 1.35 liters of water per kilogram of binder, to obtain a fire retardant mortar applicable to construction structures. Example 2.- Method of application of the fire retardant mortar of Example 1 for coating a metal column.

For the correct application of the mortar by hand, the following operation must be followed:

Place an electrowelded galvanized reinforcement mesh of dimensions 50x50x1.6 mm. set to the

Metal structure to be protected by separators and fulminating fixing, sewn by wire.

Place wooden formwork at the top and bottom of the wings of the column profile, separated from the structure a distance equal to that necessary to obtain the required fire stability according to mandatory tests (Figure 1).

If protection is desired following the shape of the column profile, formwork must be added

partial inside the wings of the profiles to formalize the perimeter of the profile (Figure 2).

Wooden formwork will be held by cats or sergeants.

The fire retardant mortar will be applied by spraying machine without using an air compressor with the

desired mixture in the non-formwork areas, this is the wings and the profiles, talochating the mortar by means of a trowel leaving it flush with the edge of the formwork.

Within 24 hours of the beginning of setting, the formwork must be removed and the empty parts filled up until the desired shape is completed by troweling.

The finish of the mortar lining may have a cube shape, as indicated in Figure 3, or the shape of the perimeter of the column profile as indicated in Figure 4.

Claims (17)

1. A fire retardant binder characterized in that it comprises:

-

gray cement, in a percentage between 60% and 64% of the total weight of the binder composition, including both limits;

-

vermiculite, in a percentage comprised between 35% and 37% of the total weight of the binder composition, including both limits;

-

bentonite, in a percentage between 0.97% and 1.03% of the total weight of the binder composition, including both limits; Y

-

at least one redispersible binder based on a copolymer of vinyl acetate and vinyl versatate, in a percentage comprised between 0.97% and 1.03% of the total weight of the binder composition, including both limits,

the sum thereof being less than 100% of the total weight of the binder formulation. 2. A flame retardant binder according to claim 1 consisting of the following formulation:

-

gray cement, in a percentage between 60% and 64% of the total weight of the binder composition, including both limits;

-

vermiculite, in a percentage comprised between 35% and 37% of the total weight of the binder composition, including both limits;

-

bentonite, in a percentage between 0.97% and 1.03% of the total weight of the binder composition, including both limits; Y

-

at least one redispersible binder based on a copolymer of vinyl acetate and vinyl versatate, in a percentage comprised between 0.97% and 1.03% of the total weight of the binder composition, including both limits,

the sum thereof being equal to 100% of the total weight of the binder formulation.

3.

 Flame retardant binder according to any one of claims 1 or 2, wherein the gray cement is of the CEM type I 52.5 N / SR.

Four.

 Flame retardant binder according to any one of claims 1 to 3, wherein the vermiculite is expanded vermiculite grade 2.

5.

 Flame retardant binder according to any one of claims 1 to 4, wherein the bentonite is standard sodium bentonite.

6.

 Flame retardant binder according to any one of claims 1 to 5, which has the following formulation: - CEM I 52.5 N / SR gray cement in 62%; - expanded grade 2 vermiculite by 36%; - 1% standard sodium bentonite; and -Redispersible binder based on copolymer of vinyl acetate and vinyl versatate in 1%.

7.

 Flame retardant mortar obtainable from the binder described in any one of the preceding claims, and water.

8.

 Fire retardant mortar according to the preceding claim, which has the following proportion: between 0.9 and 1.35 liters of water per kilogram of binder, including both limits.

9.

 Method of manufacturing the flame retardant binder described in any one of claims 1 to 6, characterized in that it comprises adding all the components at once and subjecting them to mixing until they are completely homogenized.

10.

 Method according to the preceding claim, wherein the mixing of the components is carried out by silo automation.

eleven.

 Method according to any one of claims 9 or 10, wherein the addition of the components of the binder is carried out in a weighing hopper, and the mixing thereof is carried out in a rotating drum for a time between 8 and 10 minutes. , including both limit.

12.

 Method according to any one of claims 9 to 11, wherein the binder is packaged in sacks.

A method according to any one of claims 9 to 12, wherein the binder is mixed at least with water to prepare a fire retardant mortar. 14. A method according to claim 13, wherein the binder is mixed with water in a proportion between 0.9 and 1.35 liters of water per kilogram of binder, including both limits. 15. Use of the fire retardant binder described in any one of claims 1 to 6 for manufacturing fireproof cement mortars 10.

16.

 Use of the fire retardant mortar described in any one of claims 7 or 8 for coating construction elements.

17.

 Use according to the preceding claim, wherein the constructive element is a metal structure.

SPANISH OFFICE OF THE PATENTS AND BRAND Application no .: 201131672 SPAIN Date of submission of the application: 18.10.2011 Priority Date: REPORT ON THE STATE OF THE TECHNIQUE 51 Int. Cl.: C04B14 / 20 (2006.01) C04B16 / 04 (2006.01) RELEVANT DOCUMENTS

Category

56 Documents cited Claims Affected

TO

GB 993523 A (PREVITE CO LTD) 26.05.1965, 1-17

claim 2; page 2, lines 47-50.

TO

WO 2006070960 A1 (KYUNG DONG CERATECH CO LTD et al.) 06.07.2006, 1-17

claim 1; page 10, lines 10-13; page 9, line 8; page 12, line 15; page 11,

lines 4-5.

TO

WO 2005012203 A2 (UNIV AALBORG et al.) 10.02.2005, 1-17

claims 1,7,8.

Category of the documents cited X: of particular relevance Y: of particular relevance combined with other / s of the same category A: reflects the state of the art O: refers to unwritten disclosure P: published between the priority date and the date of priority submission of the application E: previous document, but published after the date of submission of the application

This report has been prepared • for all claims • for claims no:

Date of realization of the report 04.02.2013

Examiner J. García Cernuda Gallardo Page 1/4

REPORT OF THE STATE OF THE TECHNIQUE Application number: 201131672 Minimum documentation sought (classification system followed by classification symbols) C04B Electronic databases consulted during the search (name of the database and, if possible, terms of search used) INVENES, WPI, EPODOC, XPESP, TXTEP1, TXTGB1, TXTUS2, TXTUS3, TXTUS4 State of the Art Report Page 2/4  WRITTEN OPINION Application number: 201131672 Date of Written Opinion: 04.02.2013 Statement

Novelty (Art. 6.1 LP 11/1986)

Claims 1-17 Claims IF NOT

Inventive activity (Art. 8.1 LP11 / 1986)

Claims 1-17 Claims IF NOT

The application is considered to comply with the industrial application requirement. This requirement was evaluated during the formal and technical examination phase of the application (Article 31.2 Law 11/1986).  Opinion Base.- This opinion has been made on the basis of the patent application as published. State of the Art Report Page 3/4  WRITTEN OPINION Application number: 201131672  1. Documents considered.- The documents belonging to the state of the art taken into consideration for the realization of this opinion are listed below.

Document

Publication or Identification Number publication date

D01

GB 993523 A (PREVITE CO LTD) 05/26/1965

D02

WO 2006070960 A1 (KYUNG DONG CERATECH CO LTD et al.) 06.07.2006

D03

WO 2005012203 A2 (UNIV AALBORG et al.) 02.10.2005

 2. Statement motivated according to articles 29.6 and 29.7 of the Regulations for the execution of Law 11/1986, of March 20, on Patents on novelty and inventive activity; quotes and explanations in support of this statement The invention relates to a flame retardant binder comprising from 60% to 64% of gray cement, 35 to 37% of vermiculite, 0.09% to 1.03% of bentonite and 0.97% to 1.03% of a Redispersible binder of copolymer of vinyl acetate and vinyl versatate (reiv. 1), to a mortar that can be obtained from it (reiv. 7), a method for its manufacture by mixing and homogenization (reiv. 9) and its use to make mortars (reiv. 15). Document D01 refers to improvements on bituminous compositions and sheets prepared therefrom comprising asphalt cement, mineral filler material and reinforcing fiber (reiv. 2). The filler material may include bentonites and vermiculite (p. 2 line 47-50). No redispersible binder of acetate or vinyl versatate copolymer is mentioned. Document D02 refers to a composite material covering for fire resistance and sound absorption comprising a light aggregate, a binder, fiber for absorbing general or flame retardant carbonizable sounds and additives (reiv. 1). Its content includes cement (page 10 line 10-13), vermiculite (page 9 line 8), bentonite (page 12 line 15) and polyethylene or polystyrene fiber (page 11 line 4-5) . No mention is made of vinyl acetate copolymer and vinyl versate. Document D03 refers to a method for preparing materials containing binder systems derived from amorphous silica and one or more bases and optionally additives, by mixing and curing operations (reiv. 1). It may include cements (reiv. 5), polymer fibers (reiv. 7) and bentonite and vermiculite (reiv. 8). No proportions matching those of the application are mentioned. The application is considered to meet the requirements of novelty and inventive activity in its claims 1-17, according to art. 6.1 and 8.1 of the L.P. State of the Art Report Page 4/4