FR2599664A3 - Method for manufacturing a lightweight cast structure, and material for the implementation of this method - Google Patents

Method for manufacturing a lightweight cast structure, and material for the implementation of this method Download PDF

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Publication number
FR2599664A3
FR2599664A3 FR8608290A FR8608290A FR2599664A3 FR 2599664 A3 FR2599664 A3 FR 2599664A3 FR 8608290 A FR8608290 A FR 8608290A FR 8608290 A FR8608290 A FR 8608290A FR 2599664 A3 FR2599664 A3 FR 2599664A3
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Prior art keywords
elements
manufacturing
mortar
mold
solid
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French (fr)
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Priority to FR8608290A priority Critical patent/FR2599664A3/en
Publication of FR2599664A3 publication Critical patent/FR2599664A3/en
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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
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/0008—Materials specified by a shape not covered by C04B20/0016 - C04B20/0056, e.g. nanotubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0068—Embedding lost cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0081—Embedding aggregates to obtain particular properties
    • B28B23/0087—Lightweight aggregates for making lightweight articles
    • 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
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C04B16/08—Macromolecular compounds porous, e.g. expanded polystyrene beads or microballoons
    • 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
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/08—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding porous substances
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
    • E04C5/073—Discrete reinforcing elements, e.g. fibres

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Nanotechnology (AREA)
  • Civil Engineering (AREA)
  • Moulds, Cores, Or Mandrels (AREA)

Abstract

Method for manufacturing a lightweight concrete. According to the invention, solid elements 13 are mixed into the liquid mortar 14, these elements having a lower density than the mortar and the density of the structure thus cast depending on the proportion of solid elements in the mixture.

Description

PROCEDE DE FABRICATiON D'UNE STRUCTURE MOULEE ALLEGEE.  METHOD FOR MANUFACTURING A LIGHTWEIGHT MOLDED STRUCTURE.

LT tIATERIAU POUR LA MISE EN OEUVRE DE CE PROCèDE.  LT tiATERIAU FOR THE IMPLEMENTATION OF THIS PROCESS.

L'invention concerne un procédé de fabrication d'une structure mou lét allégée, principalement un béton allégé; l'invention concerne aussi un matériau utilisable pour la mise en oeuvre de ce procédé. The invention relates to a method for manufacturing a soft, light structure, mainly a light concrete; the invention also relates to a material which can be used for the implementation of this process.

On connaît un procédé pour réduire la masse volumique du béton, consistant essentiellement à injecter des bulles de gaz dans le mortier liquidc. La mise en oeuvre de ce procédé est délicate, car il est difficile de bien maîtriser la proportion de vides et surtout leur répartition dans la masse de l'ouvrage. L'invention permet due résoudre ce type d'in convénient
Dans cet esprit, l'invention concerne essentiellement un procédé de fabrication d'une structure moulée allégée, par exemple en béton,- caractérisé en ce qu'il consiste à réaliser un mélange relativement homogène de mortier et d'éléments solides de masse volumique équivalente notablement plus faible que celle dudit mortier, avant de laisser solidifier ce dernier.A method is known for reducing the density of concrete, consisting essentially of injecting gas bubbles into the liquidc mortar. The implementation of this process is delicate, because it is difficult to control well the proportion of voids and especially their distribution in the mass of the structure. The invention makes it possible to resolve this type of inconvenience
In this spirit, the invention essentially relates to a process for manufacturing a light molded structure, for example made of concrete, - characterized in that it consists in producing a relatively homogeneous mixture of mortar and solid elements of equivalent density significantly lower than that of said mortar, before allowing it to solidify.

L'invention concerne aussi tout matériau pour alléger une structure moulée, par exemple en béton, caractérisé en ce qu'il est essentiellement constitué d'éléments solides de masse volumique équivalenterelative- ment faible par rapport à celle d'un mortier avec lequel on désire matérialiser ladite structure moulée
I1 est à noter que le terme "mortier" utilisé pour la définition de l'invention doit être compris dans son acception la plus large. En effet, si le procédé a surtout été développé pour être mis en oeuvre avec un mortier de béton, il peut aussi s' appliquer avec du plâtre ou tout mortier de plâtre, ou avec un liant ou une résine quelconque, adjuvanté ou non, armé de fibres ou non, etc... The invention also relates to any material for lightening a molded structure, for example concrete, characterized in that it consists essentially of solid elements of density which is relatively low compared to that of a mortar with which it is desired. materialize said molded structure
It should be noted that the term "mortar" used for the definition of the invention must be understood in its broadest sense. Indeed, if the process was especially developed to be implemented with a concrete mortar, it can also be applied with plaster or any plaster mortar, or with any binder or any resin, additive or not, reinforced fiber or not, etc ...

Les éléments solides précités pourront être par exemple des pièces creuses, notamment en matière plastique rigide. Dans ce cas, la masse volumique équivalente de ces éléments solides sera légèrement supérieure à celle de l'air. Les éléments pourront aussi être pleins et en matériau homogène rigide de faible masse volumique, comme par exemple une mousse synthétique rigide (polystyrène expansé). The aforementioned solid elements may for example be hollow parts, in particular of rigid plastic. In this case, the equivalent density of these solid elements will be slightly higher than that of air. The elements may also be solid and made of rigid homogeneous material of low density, such as for example a rigid synthetic foam (expanded polystyrene).

Selon une caractéristique avantageuse de 1 'invention, les éléments seront approximativement sphériques. Avec de tels éléments d'égal diamètre, on pourra théoriquement atteindre une propostion de "vides" de 74 % (correspondant au volume des sphères supposées toutes en contact) ce qui, avec un mortier de béton ordinaire de 2.400 kg/m3 permettra de rabaisser la masse volumique du béton allégé jusqu'à 625 kg/m3 (26 % en volume de mortier venant combler les espaces entre sphères). According to an advantageous characteristic of one invention, the elements will be approximately spherical. With such elements of equal diameter, we could theoretically achieve a "voids" proportion of 74% (corresponding to the volume of the spheres supposed to be all in contact) which, with an ordinary concrete mortar of 2,400 kg / m3 will allow to lower the density of lightened concrete up to 625 kg / m3 (26% by volume of mortar filling the spaces between spheres).

L'invention apparaîtra plus clairement à la lumière de la description qui va suivre, illustrant un procédé conforme à son principe, donnée uniquement à titre d'exemple et faite en référence au dessin annexé, dans lequel
- les figures 1 à 3 illustrent schématiquement les principales phases du procédé conforme à l'invention;
- la figure 4 est une vue de détail montrant une autre forme possible d'éléments légers susceptibles d'être utilisés pour la-mise en oeuvre du procédé : et
- les figures 5 et 6 illustrent d'autres variantes possibles de tels éléments.The invention will appear more clearly in the light of the description which follows, illustrating a process in accordance with its principle, given solely by way of example and made with reference to the appended drawing, in which
- Figures 1 to 3 schematically illustrate the main phases of the process according to the invention;
FIG. 4 is a detailed view showing another possible form of light elements capable of being used for the implementation of the method: and
- Figures 5 and 6 illustrate other possible variants of such elements.

En se référant aux figures 1 à 3, on a représenté un coffrage ou moule 11, ayant la forme et les dimensions d'une structure en béton léger que l'on désire fabriquer. Ce moule est de préférence relativement étanche, pour que le mortier puisse y etre injecté sous légère pression. C'est pourquoi on l'a représenté avec un couvercle 12. La mise en oeuvre du procédé de l'invention consiste à remplir le moule avec des éléments sphériques 13, tels que décrits ci-dessus (figure 1) et à refermer le couvercle 12 (figure 2) avant d'injecter le mortier 14 dont la plasticité et la granulométrie correspondent aux caractéristiques géométriques et dimensionnelles des espaces entre sphères et aux caractéristiques mécaniques demandées à la structure. Le mortier pourra à ce titre contenir des résines et/ou des fibres pour améliorer ses qualités et faciliter sa mise en place.L'injection se fera de bas en haut (figure 3) par l'orifice 15 avec -des évents 16 convenablement disposés. La mise en place du mortier dans les espaces laissés entre les sphères peut etre réalisée suivant les circonstances par d'autres moyens que l'injection sous pression décrite cidessus. On peut envisager notamment de faire pénétrer le mortier dans le moule par aspiration, ou encore tout simplement par gravité. Dans tous les cas, la mise en place du mortier dans les espaces qui lui sont réservés entre les sphères pourra etre facilitée par des vibrations appliquées au mélange, notamment des vibrations ultrasonores. Referring to Figures 1 to 3, there is shown a formwork or mold 11, having the shape and dimensions of a lightweight concrete structure that one wishes to manufacture. This mold is preferably relatively sealed, so that the mortar can be injected into it under slight pressure. This is why it has been represented with a cover 12. The implementation of the method of the invention consists in filling the mold with spherical elements 13, as described above (FIG. 1) and in closing the cover. 12 (FIG. 2) before injecting the mortar 14, the plasticity and particle size of which correspond to the geometric and dimensional characteristics of the spaces between spheres and to the mechanical characteristics required of the structure. As such, the mortar may contain resins and / or fibers to improve its qualities and facilitate its placement. The injection will be made from bottom to top (FIG. 3) through the orifice 15 with -vents 16 suitably arranged. . The placement of the mortar in the spaces left between the spheres can be carried out depending on the circumstances by other means than the pressure injection described above. It is possible in particular to envisage making the mortar penetrate into the mold by suction, or even simply by gravity. In all cases, the placement of the mortar in the spaces reserved for it between the spheres may be facilitated by vibrations applied to the mixture, in particular ultrasonic vibrations.

Si on désire réaliser un ouvrage de masse volumique comprise entre la valeur minimum indiquée ci-dessus et une valeur maximum correspondant à celle du mortier utilisé, on pourra augmenter la proportion des espaces laissés entre lus éléments légers, en utilisant de tels éléments approximativement spiériques 13a, munis de saillies 17 jouant le rôle d'écarteurs. If one wishes to carry out a work of density ranging between the minimum value indicated above and a maximum value corresponding to that of the mortar used, one can increase the proportion of the spaces left between lus light elements, by using such approximately spherical elements 13a , provided with projections 17 playing the role of spacers.

Cette confiuration est illustrée à la figure 4. On pourra aussi utiliser des éléments 13b reliés les uns aux autres par des tiges 18 de même matière, ou de matière différente, de façon à définir une configuration à mailles régulières. Ainsi, la figure 5 illustre une configuration à mailles carrées et la figure 6 illustre une configuration à mailles triangulaires. Ces éléments liés seront alors de préférence obtenus par moulage en nappes ou plaques de sorte que leur mise en oeuvre consistera simplement à disposer dans le coffrage de telles nappes les unes sur les autres avant de couler le mortier. L'écartement entre nappes pourra être assuré par des aspérités venues de matiere sur les sphères.This configuration is illustrated in FIG. 4. It is also possible to use elements 13b connected to each other by rods 18 of the same material, or of different material, so as to define a configuration with regular meshes. Thus, FIG. 5 illustrates a configuration with square meshes and FIG. 6 illustrates a configuration with triangular meshes. These linked elements will then preferably be obtained by molding in layers or plates so that their implementation will consist simply in placing in the formwork such layers one on the other before pouring the mortar. The spacing between layers may be ensured by roughness coming from the material on the spheres.

Les éléments légers pourront éventuellement assurer une part non négligeable de la résistance mécanique de ltouvrage, notamment grâce à l'utilisation des nappes décrites ci-dessus. Dans ce cas, le matériau et son épaisseur seront choisis en conséquence. Dans tous les cas, la forme sphérique des éléments leur permettra de résister dans de bonnes conditions aux sollicitations de compression.  The light elements may possibly provide a non-negligible part of the mechanical strength of the structure, in particular through the use of the plies described above. In this case, the material and its thickness will be chosen accordingly. In all cases, the spherical shape of the elements will allow them to resist compression stresses in good conditions.

Claims (16)

REVENDICATIONS 1. Procédé de fabrication d'une structure moulée allégée, par exemple en béton, caractérisé en ce qu il consiste à réaliser un mélange relativement homogène de mortier liquide (14) et d'éléments solides (13) de masse volumique équivalente notablement plus faible que celle dudit mortier, avant de laisser solidifier ce dernier. 1. A method of manufacturing a lightweight molded structure, for example concrete, characterized in that it consists in making a relatively homogeneous mixture of liquid mortar (14) and solid elements (13) of significantly lower equivalent density than that of said mortar, before allowing it to solidify. 2. Procédé de fabrication selon la revendication 1, caractérisé en ce qu'il consiste à disposer lesdits éléments (13) dans un moule (11) de ladite structure, relativement étanche, puis à injecter le mortier (14) sous pression dans ledit moule. 2. The manufacturing method according to claim 1, characterized in that it consists in placing said elements (13) in a mold (11) of said structure, relatively sealed, then in injecting the mortar (14) under pressure in said mold. . 3. Procédé de fabrication selon la revendication 1, caractérisé en ce qu'il consiste à disposer lesdits éléments -(13) dans un moule de ladite structure, relativement étanche, puis à faire pénétrer le mortier (14) dans ledit moule par aspiration. 3. The manufacturing method according to claim 1, characterized in that it consists in placing said elements - (13) in a mold of said structure, relatively sealed, then in penetrating the mortar (14) in said mold by suction. 4. Procédé de fabrication selon l'une des revendications précédentes, caractérisé en ce qu'on applique des vibrations, par exemple ultrasonores, audit mélange. 4. Manufacturing process according to one of the preceding claims, characterized in that vibrations, for example ultrasonic, are applied to said mixture. 5. Procédé de fabrication selon l'une des revendications précédentes, caractérisé en ce que lesdits éléments utilisés sont des pièces creuses, par exemple en matière plastique rigide. 5. Manufacturing method according to one of the preceding claims, characterized in that said elements used are hollow parts, for example of rigid plastic. 6. Procéde de fabrication selon l'une des revendications précédentes, caractérisé en ce que les éléments utilisés sont pleins et en matériau mousse synthétique rigide. 6. Manufacturing process according to one of the preceding claims, characterized in that the elements used are solid and made of rigid synthetic foam material. 7. Procédé de fabrication selon l'une des revendications précédentes, caractérisé en ce que lesdits éléments sont approximativement sphériques. 7. Manufacturing method according to one of the preceding claims, characterized in that said elements are approximately spherical. 8. Procédé de fabrication selon la revendication 7, caractérisé en ce que lesdits éléments approximativement sphériques (13a) sont munis de saillies (17) jouant le rôle d'écarteurs. 8. The manufacturing method according to claim 7, characterized in that said approximately spherical elements (13a) are provided with projections (17) acting as spacers. 9. Procédé de fabrication selon l'une des revendications précédentes, caractérisé en ce que des éléments (13b) utilisés sont reliés les uns aux autres par des tiges (18) de même matière, de facon à définir une configuration à mailles régulières. 9. Manufacturing method according to one of the preceding claims, characterized in that elements (13b) used are connected to each other by rods (18) of the same material, so as to define a configuration with regular meshes. 10. Procédé de fabrication selon la revendication 9, caractérisé en ce que lesdits éléments et lesdites tiges sont moulés en nappe. 10. The manufacturing method according to claim 9, characterized in that said elements and said rods are molded in sheet. 11. Matériau pour alléger une structure moulée, pour l'éxécution du procédé selon l'une des revendications précédentes, caractérisé en ce qu il est essentiellement constitué d'éléments solides (13) de masse volu mique équivalente, notablement plus faible que celle d'un mortier, destinés à être incorporés à un mortier. 11. Material for lightening a molded structure, for carrying out the method according to one of the preceding claims, characterized in that it consists essentially of solid elements (13) of equivalent density, significantly lower than that of 'a mortar, intended to be incorporated into a mortar. 12. Matériau selon la revendication 11, caractérisé en ce que des éléments précités (13) sont approximativement des pièces creuses, par exemple en matière plastique rigide, de préférence de forme sphérique. 12. Material according to claim 11, characterized in that the above-mentioned elements (13) are approximately hollow parts, for example made of rigid plastic, preferably of spherical shape. 13. Matériau selon la revendication 11, caractérisé en ce que des éléments (13) précités sont des pièces pleines en matériau de mousse synthétique rigide, de préférence de forme sphérique. 13. Material according to claim 11, characterized in that the above-mentioned elements (13) are solid parts made of rigid synthetic foam material, preferably of spherical shape. 14. Matériau selon l'une des revendications 11 à 13, caractérisé en ce que des éléments (13a) précités ont sensiblement la forme de sphères munies de saillies (17) jouant le rôle d'écarteurs. 14. Material according to one of claims 11 to 13, characterized in that the above elements (13a) have substantially the shape of spheres provided with projections (17) acting as spacers. 15. Matériau selon l'une des revendications 11 à 13, caractérisé en ce que des éléments précités (13b) sont reliés les uns aux autres par des tiges (18) de même matière, de façon à définir une configuration à mailles régulières. 15. Material according to one of claims 11 to 13, characterized in that the aforementioned elements (13b) are connected to each other by rods (18) of the same material, so as to define a configuration with regular meshes. 16. Matériau selon la revendication 15, caractérisé en ce que lesdits éléments et lesdites tiges forment des nappes obtenues préalablement par moulage.  16. Material according to claim 15, characterized in that said elements and said rods form sheets obtained beforehand by molding.
FR8608290A 1986-06-09 1986-06-09 Method for manufacturing a lightweight cast structure, and material for the implementation of this method Withdrawn FR2599664A3 (en)

Priority Applications (1)

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FR8608290A FR2599664A3 (en) 1986-06-09 1986-06-09 Method for manufacturing a lightweight cast structure, and material for the implementation of this method

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Application Number Priority Date Filing Date Title
FR8608290A FR2599664A3 (en) 1986-06-09 1986-06-09 Method for manufacturing a lightweight cast structure, and material for the implementation of this method

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FR2599664A3 true FR2599664A3 (en) 1987-12-11

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0932731A1 (en) * 1996-09-05 1999-08-04 Michael S. Rodgers Composite concrete
ITRM20120115A1 (en) * 2012-03-23 2013-09-24 Eg 07 Di Greco Ercole PROCESS AND APPARATUS FOR INTERSTIAL INFILTRATION.
WO2019086771A1 (en) 2017-11-06 2019-05-09 Vigier Romuald Modular porous core for moulding parts with a cellular structure
CN114621022A (en) * 2022-03-14 2022-06-14 武汉三源特种建材有限责任公司 Preparation method of porous concrete building material

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0932731A1 (en) * 1996-09-05 1999-08-04 Michael S. Rodgers Composite concrete
EP0932731A4 (en) * 1996-09-05 1999-11-10 Michael S Rodgers Composite concrete
ITRM20120115A1 (en) * 2012-03-23 2013-09-24 Eg 07 Di Greco Ercole PROCESS AND APPARATUS FOR INTERSTIAL INFILTRATION.
WO2019086771A1 (en) 2017-11-06 2019-05-09 Vigier Romuald Modular porous core for moulding parts with a cellular structure
CN114621022A (en) * 2022-03-14 2022-06-14 武汉三源特种建材有限责任公司 Preparation method of porous concrete building material

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