GB2139517A - Method of and apparatus for producing aerated cementitious compositions - Google Patents
Method of and apparatus for producing aerated cementitious compositions Download PDFInfo
- Publication number
- GB2139517A GB2139517A GB08410455A GB8410455A GB2139517A GB 2139517 A GB2139517 A GB 2139517A GB 08410455 A GB08410455 A GB 08410455A GB 8410455 A GB8410455 A GB 8410455A GB 2139517 A GB2139517 A GB 2139517A
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- GB
- United Kingdom
- Prior art keywords
- mixing chamber
- cement
- ingredients
- mixture
- mixing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/38—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions wherein the mixing is effected both by the action of a fluid and by directly-acting driven mechanical means, e.g. stirring means ; Producing cellular concrete
- B28C5/381—Producing cellular concrete
- B28C5/383—Producing cellular concrete comprising stirrers to effect the mixing
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
Abstract
An aerated cementitious composition is produced by feeding cement and foaming agent by feed means (e) to a mixing chamber (h, k) open to atmosphere together with a feed of liquid by means (g). The ingredients are there mixed and the wetted mixture pumped by pump (l) to a desired site, the capacity of pumping being greater than the feed rate of the ingredients into the mixing chamber such that air is drawn into the mixing chamber and entrained in the wetted mixture. <IMAGE>
Description
SPECIFICATION
Method of and Apparatus for Producing
Aerated Cementitious Compositions
This invention relates to a method of and apparatus for producing aerated cementitious compositions.
In particular, although not exclusively, the present invention relates to the production of lightweight aerated cementitious compositions for filling or partly filling voids or cavities in underground mines.
In underground mines voids or cavities of varied and indeterminate size frequently occur as
a result of mining operations. For example, cavities generally occur around roof supports
installed in mine roadways or above roof supports installed along a working face. To promote efficient working of the underground mine the cavities are usuaily filled or partly filled with
materials such as timber, broken rock or pumped cement grout. Unfortunately, difficulties are frequently experienced when filling cavities with these materials, for example, the infilling of cavities on a working face with timber can be a potentially hazardous operation as there Is a danger of rock spalling off the sides of a cavity and falling on the operators below.Cement grouts
have specific gravities of above 1.0 and because of this they are especially difficult to contain within overhead cavities particularly when the available shuttering is typically of a rudimentary
nature. Substantial quantites of cement are
required to fill large size cavities.
Also it is known for aerated or foamed cement compositions to be used in the manufacture of
lightweight building blocks, such compositions being produced by one of two alternative
methods. The foaming agent used may include one or more of the following materials: hydrolysed proteins, fatty acid salts, alkyi-aryl sulphonates, alkyl sulphates, phenol ethoxylates,
the purpose of the foaming agent is to entrap air in a mix of foaming agent, cement and water.
Foaming agents generally are based on materials which will lower surface tension of the composition and which help to maintain stability of air bubbles by slightly increasing the viscosity of the composition and by forming a stabilised skin to the bubbles. In one known method the foaming agent is added to the cement and water and the whole rigourously mixed. The foaming agent introduces and stabilises air bubbles during the mixing process. In an alternative method a stiff foam is first prepared usually in a foam tube or via a venturi. The foamer device intimately
mixes compressed air and the foaming agent solution to produce a continuous stream of stiff foam composed of small air bubbles. The stiff foam then is mixed with cement grout to produce an aerated cement grout. In both the above known methods fine or coarse aggregates may be introduced to the aerated cement grout.
Unfortunately, both the above prior known methods have disadvantages. With regard to the first disclosed method it is difficult to entrap sufficient air through a "whisking" technique to achieve both a desired density and a thixotropic characteristic. In addition, it takes a considerable period of time to whisk air into a mixture of cement grout and foaming agent. Moreover, this first technique does not lend itself to continuous operation and thereby obviates this method being used with the desirable very rapid setting cement compositions. With regard to the second disclosed method, it is a complicated manufacturing technique and therefore very difficult to operate in underground mining conditions. Also it is dependent upon two separate components. i.e., the foaming agent and the cement which must be mixed on site during the production of the aerated composition.
Furthermore, it can result in an unhomogenous aerated composition being produced.
An object of the present invention is to provide a method of and apparatus for producing aerated cementitious compositions which tend to overcome or reduced the above disclosed disadvantages encountered with known methods and apparatus.
Accordingly, the present invention provides a method of producing an aerated cementitious composition comprising the stages of feeding ingredients comprisng cement, foaming agent and liquid to a mixing chamber open to the atmosphere, mixing the ingredients fed to the mixing chamber, and pumping the wetted mixture produced to a desired site, the capacity of pumping being greater than the feed rate of ingredients into the mixing chamber such that in operation air is drawn into the mixing chamber and entrained in the wetted mixture.
Preferably, the feed rate of ingredients to the mixing chamber can be varied. It has been found that in the invention, the air drawn into the mixing chamber is compressed during pumping, and preferably there is no reduction of pressure until the point of use.
According to another aspect of the present invention apparatus is provided for carrying out the above defined method, the apparatus comprising a mixing chamber, feed means for feeding ingredients comprising cement, foaming agent and liquid to the mixing chamber, mixing means for mixing ingredients fed to the mixing chamber, pump means for pumping the wetted
mixture produced to a desired site, the rated pumping capacity of the pump means being greater than the feed rate of ingredients to the mixing chamber such that in operation air is drawn into the mixing chamber and entrained in the wetted mixture.
Preferably, the feed rate of at least a portion of the feed means can be varied.
Conveniently, a previously prepared mixture of cement and foaming agent is fed to the mixing chamber, but the invention is in no way limited to the use of such a mixture.
Preferably, the feed means comprises a drive conveyor for feeding the mixture comprising cement ad foaming agent to the mixing chamber and nozzle means for feeding liquid to the mixing chamber.
Preferably, the speed of the driven conveyor can be changed to vary the feed rate of the conveyor.
Advantageously, the driven conveyor is a screw conveyor.
Preferably, the mixing means comprises a screw conveyor arranged to urge the wetted mixture towards the pump means.
Advantageously, the screw conveyor and the pump means are driven from a common drive motor.
By way of example, one embodiment of the present invention will be described with reference to the accompanying drawing which shows a diagrammatic longitudinal section through the apparatus.
The drawing shows a motor a drivably connected to a gearbox b having a gear control lever c. One gearbox output is drivably connected to a first screw conveyor e having a delivery feed hopper dand a discharge chute arranged to feed material conveyed by the screw conveyor to a further feed hopper h for a second screw conveyor kwhich is drivably connected to a second output from the gearbox b, the h-opper h being open to atmosphere. The drive from this second output is transmitted via the screw conveyor k to a pump / having a wide throat inlet directly connected to the output of the screw conveyor k and a discharge port m connected to piping (not shown) leading to a desired site.It will be appreciated that the screw conveyor k and hopper h constitute a mixing chamber for material fed into the hopper and the screw element p of the screw conveyor k constitute a mixing means for material in the mixing chamber.
Nozzle means g are provided to feed liquid, typically water, to the mixing chamber.
In operation to produce an aerated cementitious composition a mixture comprising cement and a foaming agent is placed in the feed hopper d for the screw conveyor e. The mixture comprises a blend of hydraulic cement and powdered foaming agent. The hydraulic cement may be, for example, Portland-type cement, high alumina cement, gypsum cement or blends thereof. In addition the mixture may comprise additives to confer desired properties such as thixotropy and/or rapid acceleration of setting time. The mixture may further comprise pulverised fuel ash, blastfurnace slag, calcium oxide or calcium hydroxide, siiica or calcium carbonate. In a typical installation where the aerated cementitious composition produced is used to fill or partly fill cavities or voids in an underground mine.The mixture may comprise a quick setting cement as described and claimed in our prior British Patent Specification, No.
2,033,367. The specification discloses a quick setting cement comprising Portland Cement and by weight of Portland Cement ten to seventy percent of a mixture of calcium aluminate
material and calcium-sulphate material one fourtieth to fifteen percent by weight of at least one inorganic salt and one fiftieth to three percent
by weight of at least one of a carboxylic acid, a nhydrocarboxylic acid or a salt of either of said
acids. Reference may also be made to quick
setting cement compositions described in U.K.
Published Patent Application No. 2,1 23,808A.
In a typical installation the foaming agent
comprises a powdered surfactant capable of forming stable air bubbles in a hydraulic
cement/water environment. The foaming agent
may, for example, comprise a mixture of
hydrolysed and unhydrolysed proteins, preferably
selected for their synergistic characteristics. The
preferred foaming agent is available under the designation Cormix NCB6 Special Blend from
Cormix Limited, P.O. Box 132, Warrington,
Cheshire WA5 1 AG, England. Suitable dose rates for the foaming agent may be found by
experiment, but are preferably about 0.1 to 5%,
conveniently about 1%, by weight of the cement.
The screw conveyor e feeds the mixture
comprising cement and foam agent via the
discharge chute fto the mixing chamber
constituted by hopper h together with the screw
conveyor k, the feed falling from the chute into the hopper. Water is fed to the mixing chamber from the nozzle means g such that the ingredients fed to the mixing chamber are mixed by the action
of the mixing means constituted by the screw
element p of the screw conveyor k. A further
action of the screw conveyor k is to urge the wetted mixture towards the wide throat inlet of the pump /. The action of the pump I is to draw the wetted mixture from the mixing chamber and
pump it via discharge port m and the piping to a desired site.The rated capacity of the pump / is
greater than the rate at which the ingredients
comprising the mixture comprising cement and foaming agent and water are fed to the mixing
chamber. Thus the inlet to the pump tends to be only partially filled with wetted mixture and in
consequence air is drawn into the mixing
chamber to be mixed with the wetted mixture and fed to the pump. The action of the pump is to
produce foaming of the wetted mixture and
produce an aerated cementitious composition
which is fed via discharge port m to the desired site.
Typically, in an underground installation the aerated cementitious composition is pumped into voids or cavities which thereby are filled or
partially filled by the quickly setting composition.
The two speed facilities provided by operation of the gear lever c enables the apparatus to fill either large overhead cavities in a high-speed
mode or for filling smaller voids or cavities
existing around roadway roof supports in a lowspeed mode. Also the powder mixture comprising
cement and foaming agent lends itself to transportation in underground conditions.
It will be appreciated that the preferred mixture of hydraulic cement and foaming agent when used in conjunction with the apparatus described with reference to the accompanying drawing provides a method of filling cavities or voids in underground mines which overcomes the disadvantages associated with previously known techniques for filling cavities either with conventional materials, for example, timber or broken rock or with the previously discussed foaming cement grouts having a relatively high specific gravity.
In preferred embodiments, the present invention produces a homogenous aerated cement grout which is thixotropic until it sets in approximately five minutes. It therefore, is suitable for pumping into overhead cavities. The specific gravity of the aerated grout can be varied from approximately 0.15 to 0.40 enabling both supportive and solely void filling compositions to be produced. At a typical specific gravity of 0.2 the composition requires 100 kilograms of solid ingredients per cubic meter of cavity filled. This compares with a typical previously known unaerated grout which requires 1000 kilograms of solid ingredients (i.e., cement) per cubic meter of cavity filled.
It is foreseen that use of the present invention is not restricted to cavity filling in underground mines; it is envisaged that the present invention could find application in engineering, civil engineering, construction and building, wherever it is desired to fill a space with or otherwise use a material having the intrinsic advantages of a low density aerated cementitious composition. The composition may, for example, find use as an insulation material.
In other embodiments of the invention the mixing chamber is constituted by the pump inlet.
In such embodiments the mixing means need not urge the wetted material towards the pump means.
In further embodiments of the invention the cement and foaming agent are fed into the mixing chamber by separate feed means.
In some embodiments the foaming agent is fed into the mixing chamber with the liquid.
Claims (14)
1. A method of producing an aerated cementitious composition, comprising the stages of feeding ingredients comprising cement, foaming agent and liquid to a mixing chamber open to the atmosphere, mixing the ingredients fed to the mixing chamber, and pumping the wetted mixture produced to a desired site, the capacity of pumping being greater than the feed rate of ingredients into the mixing chamber such that in operation air is drawn into the mixing chamber and entrained in the wetted mixture.
2. A method as claimed in claim 1, wherein the feed rate of ingredients to the mixing chamber can be varied.
3. A method as claimed in claim 1 or 2, wherein the foaming agent is a mixture of
hydrolysed and unhydrolysed proteins.
4. A method as claimed in claim 1, 2 or 3, wherein the cement is selected from Portlandtype cement, high alumina cement, gypsum
cement and blends of two or more thereof.
5. A method as claimed in any one of the
preceding claims, wherein the cement also
comprises additives selected from pulverised fuel ash, blastfurnace slag, calcium oxide or hydroxide, silica and calcium carbonate.
6. A method as claimed in any one of the preceding claims, wherein the cement additionally comprises additives to provide thixotropy and/or acceleration of setting time.
7. A method as claimed in any one of the preceding claims, wherein the cement and foaming agents are fed together as a previously prepared mixture to the mixing chamber.
8. A method as claimed in claim 1, substantially as hereinbefore described.
9. Apparatus for producing an aerated cementitious composition, comprising a mixing chamber, feed means for feeding ingredients comprising cement, foaming agent and liquid to the mixing chamber, mixing means for mixing ingredients fed to the mixing chamber, pump means for pumping the wetted mixture produced to a desired site, the rated pumping capacity of the pump means being greater than the feed rate of ingredients to the mixing chamber such that in operation air is drawn into the mixing chamber and entrained in the wetted mixture.
10. Apparatus as claimed in claim 9, in which the feed rate of at least a portion of the feed means can be varied.
11. Apparatus as claimed in claim 9 or 10, in which the feed means comprises a drive conveyor for feeding a mixture comprising cement and foaming agent to the mixing chamber and nozzle means for feeding liquid to the mixing chamber.
12. Apparatus as claimed in claim 10 or 11, in which the speed of the driven conveyor can be changed to vary the feed rate of the conveyor.
13. Apparatus as claimed in claim 12, in which the driven conveyor is a screw conveyor.
14. Apparatus as claimed in any one of claims 9 to 13, in which the mixing means comprises a screw conveyor arranged to urge the wetted mixture towards the pump means.
1 5. Apparatus as claimed in claim 14 when dependent upon claim 13, in which the screw conveyors and the pump means are driven from a common drive motor.
1 6. Apparatus as claimed in claim 9, substantially as hereinbefore described with reference to the accompanying drawing.
1 7. An aerated cementitious composition produced by a method as claimed in any of claims 1 to 8 or by an apparatus as claimed in any of claims 9 to 1 6.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB08410455A GB2139517B (en) | 1983-05-05 | 1984-04-24 | Method of and apparatus for producing aerated cementitious compositions |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB838312326A GB8312326D0 (en) | 1983-05-05 | 1983-05-05 | Producing aerated cementitious compositions |
GB08410455A GB2139517B (en) | 1983-05-05 | 1984-04-24 | Method of and apparatus for producing aerated cementitious compositions |
Publications (3)
Publication Number | Publication Date |
---|---|
GB8410455D0 GB8410455D0 (en) | 1984-05-31 |
GB2139517A true GB2139517A (en) | 1984-11-14 |
GB2139517B GB2139517B (en) | 1986-07-09 |
Family
ID=26286043
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB08410455A Expired GB2139517B (en) | 1983-05-05 | 1984-04-24 | Method of and apparatus for producing aerated cementitious compositions |
Country Status (1)
Country | Link |
---|---|
GB (1) | GB2139517B (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2207365A (en) * | 1987-07-30 | 1989-02-01 | Fosroc International Ltd | A method and apparatus for producing an aerated cementitious composition |
DE4041727A1 (en) * | 1990-12-24 | 1992-07-02 | Bergwerksverband Gmbh | Quick-setting foam mortar - has pressure monitor at pressure pump connection and feed lines to control feed of dry material and or water to mixer |
AT401252B (en) * | 1991-06-11 | 1996-07-25 | Bug Betriebs & Grundbesitz | DEVICE FOR MANUFACTURING PUMPABLE MORTAR MORTARS ON THE SITE |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1389594A (en) * | 1972-11-08 | 1975-04-03 | Beken Eng Ltd | Continuous mixing machines |
GB1468811A (en) * | 1973-08-31 | 1977-03-30 | Thyssen Great Britain Ltd | Apparatus for mixing and pumping cement grout |
GB1486840A (en) * | 1973-11-14 | 1977-09-28 | Dilumelt | Method for continuously mixing a powder in a liquid and a device for the practical application of the method |
EP0019288A1 (en) * | 1979-05-17 | 1980-11-26 | Wachter KG.Hindelang Baustoffwerk Bautechnik | Method and apparatus for continuously mixing of dry and wet products, especially of dry mortar ready for use |
GB2067905A (en) * | 1980-01-22 | 1981-08-05 | Mono Pumps Eng Ltd | Method and apparatus for producing cement or plaster |
EP0062129A2 (en) * | 1981-03-27 | 1982-10-13 | Mono Pumps Limited | Method and apparatus for producing cement or plaster |
-
1984
- 1984-04-24 GB GB08410455A patent/GB2139517B/en not_active Expired
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1389594A (en) * | 1972-11-08 | 1975-04-03 | Beken Eng Ltd | Continuous mixing machines |
GB1468811A (en) * | 1973-08-31 | 1977-03-30 | Thyssen Great Britain Ltd | Apparatus for mixing and pumping cement grout |
GB1486840A (en) * | 1973-11-14 | 1977-09-28 | Dilumelt | Method for continuously mixing a powder in a liquid and a device for the practical application of the method |
EP0019288A1 (en) * | 1979-05-17 | 1980-11-26 | Wachter KG.Hindelang Baustoffwerk Bautechnik | Method and apparatus for continuously mixing of dry and wet products, especially of dry mortar ready for use |
GB2067905A (en) * | 1980-01-22 | 1981-08-05 | Mono Pumps Eng Ltd | Method and apparatus for producing cement or plaster |
EP0062129A2 (en) * | 1981-03-27 | 1982-10-13 | Mono Pumps Limited | Method and apparatus for producing cement or plaster |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2207365A (en) * | 1987-07-30 | 1989-02-01 | Fosroc International Ltd | A method and apparatus for producing an aerated cementitious composition |
GB2207365B (en) * | 1987-07-30 | 1991-09-04 | Fosroc International Ltd | A method and apparatus for producing an aerated cementitious composition |
DE4041727A1 (en) * | 1990-12-24 | 1992-07-02 | Bergwerksverband Gmbh | Quick-setting foam mortar - has pressure monitor at pressure pump connection and feed lines to control feed of dry material and or water to mixer |
AT401252B (en) * | 1991-06-11 | 1996-07-25 | Bug Betriebs & Grundbesitz | DEVICE FOR MANUFACTURING PUMPABLE MORTAR MORTARS ON THE SITE |
Also Published As
Publication number | Publication date |
---|---|
GB8410455D0 (en) | 1984-05-31 |
GB2139517B (en) | 1986-07-09 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 19980424 |