FR2495625A1 - Polypropylene bitumen blend used as binder - for concrete and prefabricated products - Google Patents

Abstract

A synthetic binder for producing concrete or prefabricated materials comprises an extruded blend of polypropylene and bitumen and 1-3 wt.%, w.r.t. blend, of ground or pulverised additives acting as oxidation catalysts, the grinding or pulverising being such as to allow anchoring or coating of the materials at 150-200 deg.C. The PP may be originally in the form of the virgin polymer or scrap. The blend may also contain PVC, EVA copolymer, polyethylene and/or waxes. The concrete contains sand, gravels, stones, vegetable or inorganic materials. It is prepd. by heating these to 150-200 deg.C in a mixer, adding the cold binder and mixing. The concrete obtd. can be used for constructing roads, sports grounds, panels and the like. Compared to bitumen, the blend has improved compression strength, tensile strength and resistance to heat and cold.

Description

DESCRIPTION
This invention consists of a synthetic binder, a concrete comprising this synthetic binder, as well as a method for manufacturing this concrete.

 The use of this concrete in the composition of which enters the synthetic binder, is very varied: production of road surfaces, sports fields, prefabricated elements of all kinds and all sizes, pavers, slabs, panels.

 The products currently used lack resistance to compression, traction, bending, and have difficulty withstanding heat, cold and the corrosive action of acids. Finally, these products are very expensive in terms of the maintenance of the works that they allow to carry out.

 This invention should make it possible to overcome these drawbacks by increasing the technical performance of the product.

 The synthetic binder, according to the invention, consists of a mixture of thermoplastic resin and additives acting as oxidizing catalyst agents.

 -Thermoplastic resin is obtained by passing a mixture of polypropylene and bitumen through an existing device in the plastic industry called a scraper or even through a densifier. Preferably, a scraper will be used in which a certain percentage of polypropylene and a certain percentage of bitumen will be incorporated in order to obtain, at the outlet of the apparatus, granules of polypropylene - bitumen.

 - The additives used are alumina, feldspar, kaolin, perlite, silica, and are involved in the mixture in a proportion varying from 1X to 3X of the weight of thermoplastic resin.

 The binder is obtained by bringing the entire resin mixture plus additives to temperatures varying from 150 to 200 C.

 This binder differs from existing ones, such as bitumen, by a clear technical improvement in terms of resistance to compression, traction, bending, heat and cold, thanks to clearly superior characteristics.

 Concrete, in accordance with the invention, is obtained by adding to the abovementioned synthetic binder, materials such as stones, gravel, sands, minerals, plants.

 In the composition of this concrete, the binder is involved in the proportion of 3X to 10% of the weight of the aforementioned materials used.

 This concrete will be mainly used in the manufacture of all coatings for all uses, in particular for roads, sports grounds, industrial floors, as well as for the manufacture of prefabricated elements of all shapes and sizes, due to its technical characteristics clearly superior to those of the products currently used.

The process for manufacturing the synthetic binder is as follows:
Polypropylene mixed with a certain proportion of bitumen is introduced into a scraper, at the outlet of which the new product thus created, polypropylene - bitumen, is recovered in the form of granules.

This polypropylene - bitumen is then introduced into a mill in which it is pulverized. On leaving the mill, the polypropylene - bitumen, a new thermoplastic resin3 is introduced into a mixer with the additives such as alumina, feldspar, kaolin, perlite, silica, the latter intervening in the mixture in a proportion varying from 1X to 3% of the weight of thermoplastic resin
This binder is manufactured cold using the materials commonly used in the plastic industry such as a scaler, densifier, grinder, mixer, and is in the form of powder which can be delivered to the user either in bulk or in The polypropylene and bitumen used can have a noble origin or come from waste or decommissioned in recovery. Polypropylene - bitumen can also be incorporated, according to the needs of the user, thermoplastic resins such as EVA,
Polyethylene, PVC, Waxes.

 If, for example, we choose the proportion of 1V of the weight of the thermoplastic resins for the additives, we will have the following distribution for 1 kg of additives: 250 g of alumina, or 252, 150 G of feldspar, or 15%, 150 g of kaolin, or 15,150 g of perlite or 15% and 300 g of silica or 30%. The spraying or grinding of the resin and the additives promotes the coating and the bonding of the materials used at temperatures varying from 1500 to 2000 not altering the plasticizer of the resins.

 By varying the additive percentages from 1% to 32, the uses of the product can be varied.

 This binder will be interesting for recycling companies at the manufacturing level, and for public works, construction or building companies at the usage level.

The invention also consists of a concrete containing the aforementioned binder and already described above. This concrete according to the invention breaks down as follows:
- Materials such as stones, gravel, sand, plants or minerals, etc.

 - The aforementioned synthetic binder, this intervening in a proportion varying from 3X to the weight of the aforementioned materials used.

The process for manufacturing this concrete is as follows, in accordance with the invention:
your aforementioned ci4Essus materials used are heated between 150 and 2000 C in a mixing drum. Then a quantity of cold binder is incorporated into the mixer in the proportion of 3% to 10% of the weight of the materials, as required, then the mixture is stored until it is used as is done for bitumen for example.

 The consistency of this concrete favors the production of pre-molded elements, especially since the cooling is rapid.

 The materials which can be used for the manufacture of the concrete according to the invention are the following: sands, gravels, stones, plants or metals in all their forms, basaites, porphyry limestones, dolomites, sands of sea, deserts or rivers, waste marble, gum, pozzolan, perlite, cork, vermiculite, expanded clay etc.

 If the materials used are light, that is to say a weight lower than 1,500 Kgs with M3, and whatever these materials, it is necessary to be based on 2,000 Kgs with M3 to calculate the percentage of synthetic binder (which can vary from 3% to 10%).

Concrete thus produced has the following characteristics:
-Resistance to compression: 240 bars (for 5CM thickness, grain size 0/10)
- Heat resistance: Marshall 600 test: 4,600 Kgs (In comparison, bitumen resists only 730 Kgs)
- Resistance to cold: no breakage for a test at -40.

- Flexural strength: 120 bars
- Tensile strength in Brazilian: 40 bars
- Average tensile-flexural strength: 50 to 70 bars allowing the concrete to acquire the desired flexibility.

 - Perfect resistance to acids, oils, kerosene, diesel, sea water.

 The concrete according to the invention can be colored in the mass and does not require for its manufacture that the use of current equipment.

The possibilities of using this concrete are unlimited:
- Roads, car parks, aerodromes, sports grounds, industrial floors for all uses, prefabricated elements: slabs, panels, paving stones, etc.

this list of examples of application of the product not being limiting.

 It is important to also specify that many variants are possible in the production of the product, according to the envisaged uses, taking into account the possibilities of variation of the percentages either at the level of the different components or at the level of temperatures, on the one hand, and taking into account on the other hand the possibility of using a whole range of materials of which the list given previously is not exhaustive.

Claims (4)

R E V E N D I C A T I O N S  1 / Synthetic binder participating in the manufacture of concrete or prefabricated elements, characterized in that it comprises:  - A ther @ oplastic resin constituted by polypropylene bitumen, new molecule resulting from a mixture of polypropy @ lene and bitumen passed in extruder, in noble form or waste, or of recovery, crushed or pulverized,  - And crushed or pulverized additives, playing the role of oxidizing catalyst agents., - such as: alumina, feldspar, kaolin, etc., these additives entering the mixture in a proportion varying from 1% to 3Z of the resin weight, grinding and spraying can allow the attachment and coating of materials at temperatures varying from 150 to 200 C.  21 Binder according to claim 1 characterized in that the polypropylene-bitumen can be mixed in various percentages with P.V.C, E.V.A, polyethylene, waxes.  3 / Concrete allowing various coatings or prefabricated elements to be produced, characterized in that it comprises:  - Various materials such as sand, gravel, stones, plants or minerals of all kinds,  - And a synthetic binder in accordance with one of claims 1 and 2, intervening in the proportion of 3% to 10% of the weight of the abovementioned materials used  4J A process used to manufacture the concrete according to claim 3, characterized in that the cold binder is introduced into a mixer with the materials previously heated to between 150 and 200 C, and that the product thus obtained after kneading is stored for the purpose of its use.  R E V E N D I C A T I O N S  5 / A thermoplastic resin used in the composition of the synthetic binder according to claims I and 2, characterized in that it consists of a mixture of polypropylene and bitumen passed through an extruder or other similar material, under noble form or of waste, to become a new polypropylene-bitumen molecule.  6 / a process for manufacturing the polypropylene bitumen molecule, characterized in that it suffices to introduce any mixture of polypropylene and bitu @ e into an extruder @@ @@ de sifier or tou @ other similar material.  7 / A thermoplastic resin according to claim 5, characterized in that it is possible to partially replace, polypropylene, by any other thermoplastic resin such as for example polyethylene, E.V.A., P.V.C., waxes.