GB2449407A - Raw mix for producing constructional materials and articles - Google Patents

Abstract

The invention can be used for producing multipurpose constructional materials and articles from raw mixes containing foamed vermiculite in the form of an aggregate. Said invention makes it possible to increase the physico-mechanical and heat insulation properties of the produced materials and articles and to reduce the weight loads applied to structural elements of buildings and constructions. The inventive raw mix comprises cement, foamed vermiculite, a mineral batch and water. The mineral batch is embodied in the form of a dry mix consisting of one or two materials which are selected form a first group comprising sand, expended clay and broken stone, and one or two materials selected from a second group comprising powder lime, gypsum and clay. In a two-component batch weight fractions are equal to 1.0 and 0.1-1.5 respectively. In a three-component batch, the weight fractions are equal to 0.95-0.05, 0.05-0.95 and 0.1-1.5 or 1.0, 1.9-0.1 and 0.1-1.9, respectively. In a four-component batch, the weight fractions are equal to 0.95-0.1, 0.95-0.05, 1.9-0.1 and 0.1-1.9, respectively. The mix has the following component ratio: 8.25 mass% cement, 5-21 mass% foamed vermiculite and 13-42 mass% mineral batch, the rest being water.

Description

Crude Mixture used to fabricate Construction Materials and Products

Background of the invention

The present Invention pertains to construction materials producing industry and namely to raw mixture with inorganic fillers and binding materials, and could be used to fabricate construction materials and products intended for multiple purposes.

The present Invention aims to enhance the efficiency of using construction raw mixtures including expanded vermiculite as a light mineral porous filler to handle the urgent task of making environmentally friendly non-combustible warmth-keeping and power-saving material and structures for construction sector.

There is known concrete mixture containing (weight percent concentration): 16.6-24.9 of cement, 40.3-46.1 of coarse aggregate i.e. river gravel, 17.4- 25.3 of quartz sand, 0.9-25 of expanded vermiculite production waste with grain size less than 2.5 mm, 0.9-2.5 of vermiculite rock with grain size under 2.5 mm, and water (SU 1414830, CO4B 28/04, 23.06.1986).

Disadvantages of the known mixture consist in the complexity of selecting grain-size distribution of expanded vermiculite production waste and vermiculite rock including partial material retained on sieve with openings from 1.25 mm to less than 0.14 mm. In addition to mixing all the components, the concrete mixer would grind light vermiculite grains, while subsequent pouring of the crude mixture into the mould and its vibration would be accompanied by moving of part of vermiculite grains into upper area of the mixture, which would result in essential unevenness of the structure within the concrete volume and make its service data inferior.

There is known crude mixture intended to fabricate insulating construction material containing (weight percent concentration): 12.36 -20.03 of Portland cement, 49.5 -60.39 of expanded vermiculite, 0.079 -0.083 of froth concentrate Neopor and 27 -18 -30.03 of water. Insulating material fabricated of such mixture will have compression strength of 4 -17 MPa, density of 286 -487 kg/rn3, heat conductivity of 0.063 -0.095 Wt/(rn K), flame resistance of 10 thermal cycles at 600 C (RU 2194684, CO4B 38/08, 24/14, 25.07.1997).

Disadvantages of this crude mixture consist in the fact that expanded vermiculite, once intermixed with foamed cement, would unevenly spread within its volume, which makes obtaining of building mortars, concretes and products on their basis difficult. Materials obtained following the known mixture setting have significant spreads of values characterizing strength, heat conductivity and other properties, which makes efficiency of their use for construction inferior.

There is known dry mix containing Portland cement M400D5 as a binding material, and filling material represented by expanded vermiculite M 100 with the following particle size distribution according to partial sieve residue: 5.0 mm -5%, 0.6 mm -55%, less than 0.6 mm -40%, with the following ratios of components (weight percent concentration): Portland cement 49 -83, expanded vermiculite 51 -17. The dry mix will be supplemented with water and used as internal and external finishing heat-insulating layers in the event of prefabrication of building components and directly at construction sites (RU 2162067, CO4B 28/04, 05.06.1998).

A disadvantage of the known mix is that heat-insulating layers obtained on its basis have loose structure, surface of the layers scales off due to sloughing of vermiculite particles, which adversely affects service performance of products with such layers.

There is known heat-insulating concrete composition that includes cementing material and light mix consisting of expanded vermiculite and expanded perlite with their ratio not exceeding 2: 1 weight parts. In the concrete composition, the cementing material-to- light mix ratio approximates 4: 1 weight parts. The cementing material represents a hydraulic binding agent with accelerating agent and includes (weight percent concentration): Portland cement, gypsum plaster and dehydrate gypsum with their relationship approximating 5:4:1 or aluminous cement and gypsum plaster with their relationship approximating 11:5. Concrete composition could also include (weight percent concentration): 0.5-2 of air entraining agent and 0.3-1.5 of surfactant. Liquid mortar obtained following intermixing of all components with water will be used for applying heat-insulating and repair coatings to building structures (US 6290769, 106/675, CO4B 038/08, 18.09.2001).

The major disadvantage of the know composition consists in the fact that the coatings obtained on its basis will, once dried, have density exceeding 700 kg/rn3, which will not allow for reducing their thermal conductivity and accordingly their thickness and weight. Increasing the amount of vermiculite or perlite in the composition in order to enhance heat-insulating properties of the coatings will simultaneously call for increase of the cementing material weight as failure to do this will affect strength properties of coatings that, once dried, will reveal cracks and disintegration.

Particularly close to the claimed raw mixture capable of handling the set engineering problem is raw mixture representing a composition that includes (parts by volume): 2.0 of cement, 10.0 of expanded vermiculite and 2.6 of water? The composition could further contain (parts by volume): 1.0 -5.0 of calcined mica. The composition could include cement mix consisting of Portland cement (65%) and high-alumina cement (35%). Apart from this, various options of the composition could contain the following additives (part by volume): 0.1 of plastifier, 0.2 of 50% polyvinyl-acetate emulsion or 0.2 of 50% acrylic emulsion, 0.02 of setting accelerator. To enhance water resistance, protective and decorative properties of products fabricated with the use of this composition (columns, posts, borders etc.), the composition could be supplemented with water-repellent agents and pigments (GB 2266886, CO4B 14/20, EO4H 17/20, 11.11.1993 r.).

Disadvantages of the known raw mixture consist in the fact, that heightened strength properties of products fabricated of it will, as it is the case with the aforementioned counterparts, be ensured at the expense of increasing the weight of binding components, which makes the products heavier, and their heat-insulating properties lower. Use of calcined mica will make the mixture more costly, require supplementing it with special-purpose additives containing organic combustible substances as it will become loose and could only be used to fill hollow structures, which will essentially restrict its application in construction, e.g. in applying non-combustible heat-insulating coatings, preparation of warm mortars, fabrication of molded heat-insulating and structurally-heat-insulating non-combustible products, and will not allow for efficiently using unique thermal-physical and weight properties of expanded vermiculite in creating new materials and products for building industry and in particular for enclosing structures that combine enhanced values of bearing capacity and thermal resistance coefficient.

According to the analysis, characteristic of raw construction mixtures based on expanded vermiculite is a certain controversy between requirements for reducing thermal conductivity and ensuring necessary strength and minimizing weight of materials and products fabricated of such mixtures.

Summary of the Invention

A task of the invention consists in improvement of service performances of materials and products based on the claimed raw mixture, widening functional capabilities of its application for enhancing heat- and power-saving characteristics of both newly erected and repaired buildings and structures.

Sought-after technical result consists in enhancing physical-mechanical and heat-insulating properties of finished materials and products with ensuring the potential for reducing weight loads on bearing members of buildings and structures.

To resolve the set problem, raw mixture consisting of cement, expanded vermiculite, mineral charge and water shall contain mineral charge represented by dry mix of a single material or any two materials chosen out of a group including sand, expanded clay, crushed stone and a single or any two materials chosen out of a group including: powder lime, gypsum and clay with the following components relationship determined on the basis of the expressions: As concerns charge consisting of any material chosen out of a group including sand, expanded clay, crushed stone and any single material chosen out of a group including powder lime, gypsum, clay Ax+By x=1.0 y=0.1 -1.5, where A -any single material chosen out of a group including sand, expanded clay, crushed stone; B -any single material chosen out of a group including powder lime, gypsum, clay; x -mass fraction of material A; y -mass fraction of material B; As concerns charge consisting of any two materials, chosen out of a group including, sand, expanded clay, crushed stone and any single materials chosen out of a group including powder lime, gypsum, clay (Alx* + A*x*) + By x = 0.05 -0.95 V = 0.1-1.5, where A -any first material chosen out of a group including sand, expanded clay, crushed stone; A* -any second material chosen out of a group including sand, expanded clay, crushed stone; B any single material chosen out of a group including powder lime, gypsum, clay; x' -mass fraction of material A*; y -mass fraction of material B; As concerns charge consisting of any single material chosen out of a group including sand, expanded clay, crushed stone and any two materials chosen out of a group including powder lime, gypsum, clay Ax + (B2y* + B*y*) x = 1,0 y* = 0,1-1,9 where A -any material chosen out of a group including sand, expanded clay, crushed stone; B -any first material chosen out of a group including powder lime, gypsum, clay; B* -any second material chosen out of a group including powder lime, gypsum, clay; x -mass fraction of material A; y* -mass fraction of material 8*; for charge consisting of any two materials chosen out of a group including, sand, expanded clay, crushed stone and any two materials chosen out of a group including powder lime, gypsum, clay (Alx* + A*x*) + (B2y* + B*y*) x = 0,05 -0,95 y* = 0,1-1,9 rae A -any first material chosen out of a group including sand, expanded clay, crushed stone; -any second material chosen out of a group including sand, expanded clay, crushed stone; B -any first material chosen out of a group including powder lime, gypsum, clay; B* -any second material chosen out of a group including powder lime, gypsum, clay; x -mass fraction of material A*; y* -mass fraction of material B*; with the following relationship between crude mixture components (weight percent concentration): Cement 8 -25 Expanded vermiculite 5 -21 Mineral charge 13 -42 Water the rest Combinations of materials and mass ratios indicated for the proposed raw mix have been obtained experimentally and provide the possibility of preparing compositions with consistencies varying from liquid building mortars and concretes (having minimum content of dry components in the mix equal to 26 of mass percent: 8 of cement, 5 of vermiculite, 13 of mineral charge), to semi-dry molding compounds (having maximum content of dry components in the mix equal to 88 of mass percent: 25 of cement, 21 of vermiculite, 42 of mineral charge).

Should the content of dry components in the composition be less than 26 mass percent, it will represent a liquid mix with excessive amount of free water, which will lead to swelling of the expanded vermiculite grains and breakdown of the mix into liquid and dispersed phase. Coatings and cracks obtained of it will, once dried, poorly stick, slough and crack.

Should the composition contain dry components accounting for more than 88 mass percent, it will represent poorly moisturized loose mass with amount of water not sufficient to form binding gel within its volume so that to make products formed of it comply with standard requirements for heat conductivity and strength. Products having the required porosity turn out to be brittle, while porosity increase results in essential decline of porosity, increase of heat conductivity, weight and cost of the products.

The raw mix contains vermiculite as per GOST 12865 "Expanded Vermiculite" (grain size under 10 mm and bulk powder density no more than 200 kg/rn3) and cement as per GOST 22236 "Portland Cement and Portland-Blastfurnace Cement (degree of fineness -no less than 85% of the mass passes through a sieve with mesh No. 008, which corresponds to specific surface area of 2,500- 3,000cm2/g).

As established experimentally, in the compositions of cement with expanded vermiculite and calcined vermiculite mica (porous low-strength materials with multi-layer scale structure of grains) irrespective of mixing and water wetting techniques, vermiculite and mica grains fail to yield thin and homogeneous film of cement gel, prevent vermiculite and mica from impregnation and swelling, which adversely affects weight, strength and heat-transfer properties of materials and products following cement stone formation.

Supplementation of the vermiculite-cement composition with mineral charge including, according to the Invention, from two to four components and consisting of strong filling aggregate grains and finely-dispersed binding material will allow, given water added, for obtaining the binding material gel capable of evenly spreading within the mix volume and of forming a thin film on the surface of all granular components.

According to the intended purpose of a material or product (liquid, semi-solid finishing mortar or masonry mass, semi-dry mass, blocks molded of it etc.), by choosing mineral charge out of the above combinations of components, the composite binding material will be assigned both composition and density contributing to its lower penetration into expanded vermiculite grains. This will result in reducing the binding material weight required to link dispersed components of the structure together and make it adequately strong following its curing. Essential volume of closed air cavities retained in vermiculite grains will be responsible for heightened heat-insulating properties of the structure.

Application of mineral charge with the number of components exceeding four (more than two filling aggregates and two binding materials) is not expedient as this will complicate mix preparation technology leaving its functional capabilities almost unchanged.

Detailed Description

Characteristics of materials used in the mineral charge for the proposed raw mixture consist in the following.

Powder lime (GOST 9179 "Builder's Lime") will be used as a light component with bulk loose density of 350-500 kg/rn3 (2 -3 lighter than cement), which will offer higher bulk volumetric content of the composite binding material and its more even and fast distribution when agitated within the mix volume due to the reduction of its density and viscosity.

Gypsum (GOST 125 "Binding Gypsum-based Materials) will be applied as component possessing, in comparison with cement, higher water demand and rate of setting, which will lower impregnation and swelling of the expanded vermiculite grains and speed up curing of the composite binding material.

Clay will be introduced as a component contributing to coating the expanded vermiculite grains with thin film of the composite binding material, enhancing plasticity of a mix varying in terms of consistency when agitated, applied to various surfaces or used to making molded products. Practically used could be natural fine-grained aluminosilicate clays belonging to kaolinite and montmorillonite group of clays (bentonites).

Grains of hard filling aggregate (sand, expanded clay, crushed stone) within the structure of materials and products manufactured of the proposed mix will be non-deformable nodes of a structure making it stronger and intersticed with expanded vermiculite grains having surface area that exceeds hundreds of times surface area of the aforementioned nodes and forming porous volume of the structure.

Combining a granulometric composition of various hard filling aggregate (sand-expanded clay, sand-crushed stone, expanded clay-crushed stone) with vermiculite will allow, by changing their surface wetting degree, for choosing the required mix consistency, optimize its moisture, reduce weight of the composite binding material and re-allocate it for forming thin-film adhesive layers between the expanded vermiculite grains thus ensuring the required strength of the structure as a whole.

Sand (GOST 8736 "Sand Construction Activity") will be used as a component of mixes predominantly intended for preparing cover, hot vermiculite-sand mortars and mason's masses. Apart from this, sand fractionation will allow for fabricating molded heat-insulated structural products with superior surface quality enabling to reduce the amount of mix used for masonry and surface finish.

Expanded clay (GOST 9757 "Artificial Porous Gravel, Crushed Stone and Sand") will be used as a light component with bulk loose density of 250-800 kg/rn3 (2-6 times lighter than sand). Wide range of expanded clay particle-size distribution varying from fine sand to grains as large as 20-40 mm allows for reducing the mass of expanded vermiculite and binding material not affecting low heat conductivity of the structure and for using such compositions of the mix to prepare heat-insulating mortars and concretes, to mold heat-insulating and heat-insulating-structural products.

Crushed stone (GOST 8267 "Crushed Stone and Gravel of Dense Rocks for Construction Activities" and GOST 22263 "Crushed Stone and Sand of Porous Rocks") contained in the proposed crude mix will discharge functions similar to those of sand and expanded clay. Apart from this, natural crushed stone will, once used, contribute to enhancing strength and lowering fabrication cost of heat-insulating structural concretes and products made of local materials.

Granulometric composition of the above graded filling aggregates will be assigned based on the intended purpose of target materials and products and in compliance with applicable building regulations.

Specific Examples

Table 1 shows examples of the proposed crude mix compositions on the basis of 1,000 kg of crude mix per batch. When using mixers with lower feed per batch, the batch weight will accordingly be adjusted, and mixing period will experimentally be determined with due regard for mixing equipment type.

Table 2 shows properties of materials manufactured of the proposed crude mix and of the crude mix progenitor (subject to tests were samples aged as long as 28 days and more dried to their permanent weight).

Example 1. Compositions of types Ax + By Composition 1. Drum mixer will be loaded with 115 kg of fine-fraction river sand having fineness modulus Mk = 2.0 -1.5 that, whilst constantly stirred, will be supplemented with 15 kg of powder lime (bulk density of 390 kg/rn3, CaO MgO content = 60.3 %), 80 kg of Portland cement PC500-D0 and 200 I of water. Afterwards, 50 kg of 1 -2.5 mm fraction expanded vermiculite will gradually be poured (bulk density of 120 kg/rn3), stirred during 2.5 -3 minutes, and remaining water will be added. The obtained mass will with the help of pneumatic sprayer be applied to porous brick and concrete surfaces to obtain heat-and sound-insulating coating.

Compositions 2-5 will be prepared similarly to composition 1, though with a higher concentration. Used for compositions 2 and 3 will be medium-fraction river sand with Mk = 2.5 -2.0, for compositions 4 and 5 -coarse-fraction river sand with Mk = 2.5 -3.25. Mortar mixes of compositions 2 and 3 will manually be applied to concrete surfaces when making warm floors, heat-and sound-insulating partitions and ceiling structures. Mixes of compositions 4 and will be used as a semi-dry charge for molding unit structural heat-insulating blocks, plates and other products by 3D vibromolding.

Compositions 6 and 7 will be prepared similarly to composition 1, but composition 6 will instead of powder lime be prepared with the use of normally curing middle-ground gypsum building plaster of brand G-5, whereas composition 7 will be prepared with use of fine-ground ductile clay of brand LT-1 (TU 14-3-8-152-75). A mixture of composition 6 will be used to manufacture thick-layer heat-insulating plaster having a number of fast-curing layers, whereas mix 7 will be used to manufacture heavy-duty heat-insulating plaster.

Compositions 8-11 with mineral charge including expanded clay as a hard aggregate will be prepared in gravity mixer. Brands of cement, powder lime and vermiculite will be assumed according to composition 1, gypsum brand -according to composition 6, and clay brand -according to composition 7. To prepare composition 8, the mixer will be loaded with 350 kg of expanded clay (5 -10 mm fraction, loose gravity of 450 kg/rn3), whilst constantly stirred, the above mix will be supplemented with 100 I of water, 50 kg of powder lime and 200 kg of Portland cement. 1 -1.5 minutes later, the mix will be supplemented with the rest of water, 180 kg of expanded vermiculite added gradually and agitated during 2 -2.5 minutes. The mix will be used to manufacture vibrocompressed structural heat-insulating wall and partition components. Compositions 9, 10 and 11 will be prepared similarly to composition 8. Composition 9 will be used as a filling aggregate in hollow structural blocks. Composition 10 will be used to manufacture structural heat-insulating molded products, while composition 11 will be used a light concrete mixture.

compositions 12-15 with mineral charge including crushed stone as a hard aggregate will be prepared in planetary-rotary mixer. Brands of cement, powder lime and vermiculite will be assumed according to composition 1, gypsum brand -according to composition 6. Composition 15 will be prepared with the use of ductile clay ON-i containing (mass percentage): Si02 -50.2, Al203 -33.0, Fe203 -1.17 (Ukraine). To prepare composition 12, the mixer will be loaded with 200 kg of crushed limestone (5 -10 mm fraction, loose density of 1,100 kg/rn3), whilst constantly stirring, the above mix will be supplemented with 50 I of water, 120 kg of powder lime and 120 kg of Portland cement. 1-1.5 minutes later, the above mix will be supplemented with the rest of water, 180 kg of expanded vermiculite added gradually and stirred during 1.5 -2 minutes. Compositions 12 and 13 will be used as concrete mixture to arrange various structural heat-insulating lower strata.

Composition 14 will be used as a filling aggregate for hollow structural blocks.

Composition 15 will be used to fabricate molded products.

Example 2. Compositions of type (Aix* + A*x*) + By.

Compositions 16-20 with mineral charge including filling aggregate of sand mixed with expanded clay will be prepared in planetary mixer. To prepare composition 16, the mixer will be loaded with 40 kg of dolomite sand (fine fraction with fineness modulus Mk = 2.0 -1.5) and 70 kg of expanded clay sand (fraction under 2.5 mm, loose gravity of 550 kg/rn3), whilst constantly stirring, the above mix will be supplemented with 120 I of water, 20 kg of powder lime (loose gravity of 420 kg/rn3, CaO + MgO content of 65%) plus 80 kg of Portland cement PC 500-D5-PL (with up to 5% of plasticized cement added). 1 -1.5 minutes later, the above mix will be supplemented with 100 I of water, 50 kg of expanded vermiculite (size of particles as large as 1.5 -2.5 mm, loose density of 110 kg/rn3) to gradually be poured and the rest of water whilst stirring the whole mix during 2 -3 minutes. The mortar mix will be applied to various surfaces to obtain heat-insulating and flame resistant finish.

Composition 17 will be prepared similarly and used to predominantly obtain surface coatings with lime-cement plaster. Composition 18 will be prepared with the use of Portland cement PC 500-D20-B (with up to 20% of fast-curing cement added), coarse sand (with fineness modulus Mk = 3.25) out of screened crushed limestone and 10 -20 mm fraction expanded clay. The rest of the components will be similar to those used to prepare composition 17.

The obtained mixture will be used to fill hollow endosing structures. As distinct from composition 18, composition 19 will be prepared using gypsum of brand G-5, and the obtained semi-dry mixture will be used to manufacture solid and hollow heat-insulating and structural heat-insulating unit blocks by 3D vibromolding method. Composition 20 includes: Portland cement PC 400-DO, 2.5 -5 mm fraction vermiculite, medium-fraction river sand, 10 -20 mm fraction expanded clay and fine bentonite clay containing (mass percentage): 59.77 of Si02, 19.80 of Al203, 4.22 of Fe203, 2.95 of MgO, 1.94 of K20 (Deposit 10 Khutor, Russia). Clay, once mixed with tempering water, will be introduced into a mix of dry components and constantly stirred to obtain homogeneous mass to be used for molding porous structural heat-insulating products.

Compositions 21-23 will be prepared in planetary mixer with mineral charge including filling aggregate of porous limestone cement-crushed stone mix (1.25 -2.5 mm fraction sand, 5 -10 mm fraction crushed stone). The rest of the components will be as follows: gypsum of brand G-3 V 11(10w-early-strength, middle ground); powder lime (loose density of 400 kg/rn3, content of CaO + MgO = 65 %); clay of brand LTPK-1 (semi-acid, content of Al203 no less than 23 mass percent); Portland-blastfurnace cement ShPC 400; expanded vermiculite (1.5 -5 mm fraction, loose gravity of 110 kg/m3).

To prepare composition 21, mixer will be loaded with 100 kg of sand and 120 kg of porous crushed limestone, 50 kg of powder lime, constantly stirred when supplementing 100 I of water and kg of Portland-blastfurnace cement. 1 -1.5 minutes later, the above mix will be supplemented with 50 I of water, 210 kg of expanded vermiculite to be gradually poured, the rest of the water and agitated during 1.5 -2 minutes. The obtained mass will be used to mold structural heat- insulating products. Mixes 22 and 23 will be prepared similarly to mix 21 and used respectively for filling hollow blocks and for manufacturing structural heat-insulating concrete bases.

Compositions 24-27 will be prepared in planetary mixer with mineral charge including filling aggregate represented by expanded clay (2.5 -5 mm fraction, loose gravity of 650 kg/rn3) intermixed with crushed stone of porous shell limestone (5 -10 mm fraction). The rest of components: gypsum of brand G-7 A HI (fast-curing, fine-ground); powder lime (loose gravity of 450 kg/rn3, content of CaO + MgO = 63 %); the Chassov-Yarski pit ductile clay containing (mass percent): Si02 -51,6, A1203 -33,32, Ti02-1,37, Fe203 - 0,90, CaO -0,53, MgO -0,57, K20 -2,59 (Ukraine); Portland cement PC 500-D20-GF (with additives accounting for up to 20%, hydrophobizated); expanded vermiculite (1.5 -5 mm fraction, loose gravity of 110 kg/rn3).

Sequence of the mixer operations: loading of charge components with cement, introducing part of water to moisturize the mix, introducing expanded vermiculite and the rest of water and agitating to obtain a homogeneous mass. Composition 24 will be used to fill hollow blocks and enclosing structures. Compositions 25-27 will be used to mould porous heat-insulating and structural heat-insulating unit wall and partition blocks.

Example 3. Compositions of type Ax + (B2y* + B*y*).

Compositions 28-31 will be prepared in impeller mixer with mineral charge comprising lime-gypsum mix as a binding material. To prepare composition 28, drum mixer will be loaded with 90 kg of fine-fraction river sand with fineness modulus of Mk = 2.0 -1.5, whilst constantly stirred, will be supplemented with 20 kg of powder lime (loose gravity of 390 kg/rn3, content of CaO MgO = 60.3 %), gypsum of brand G- 5 V A LU (slow-setting, fine-ground) and 80 kg of Portland cement PC500-D0. Still running mixer will be supplemented with 250 I of water, 50 kg of expanded vermiculite (0.5 -1 mm fraction, loose gravity of 122 kg/m3) graduallypoured and agitated during 2.5 -3 minutes supplementing the rest of water. The obtained mass will, with the help of an air sprayer, be applied to porous brick and concrete surface to make the coating heat-and sound-insulating. Mass made of composition 29 has stiffer consistency and could be used as warm masonry and finishing mortar. Compositions 30 and 31 will be prepared in the same sequence as composition 28 using respectively 2.5 -5 mm fraction expanded clay and 5 -mm fraction dolomite crushed stone. Composition 30 will be used as a fluid concrete mixture, whereas composition 31 mass will be used to mold structural heat-insulating wall components.

Compositions 32-35 will be prepared in gravity batch mixer with mineral charge comprising lime-clayey mixture as a binding material. Source components: 5 -10 mm fraction expanded vermiculite having loose density of kg/rn3; Portland cement PC 500-DO; medium-fraction mountain sand with MK = 2.5 -2.0; 5 -10 mm fraction haydite expanded clay having loose density of 500 kg/rn3; 5 -10 mm fraction crushed lime and dolomite stone; powder lime having loose density of 420 kg/rn3; ductile clay ON-i, containing (mass percent): Si02 -50.2, A1203 -33.0, Fe203 -1.17 (Ukraine). Operation sequence of the mixer: loading of charge components and cement, adding part of water to wet the mix, adding expanded vermiculite and the rest of water and agitating to obtain homogeneous mass. With the help of an air sprayer, composition 32 will be applied to porous brick and concrete surfaces to obtain heat-and sound-insulating coating. Composition 33 will be used to fill hollow blocks, mix made of composition 34 will be used to mold structural heat-insulating products; composition 35 will be used as warm masonry and finishing mortar.

Compositions 36-39 will be prepared in planetary mixer with mineral charge comprising gypsum intermixed with clay as a binding material. Also used will be gypsum of brand G-5 B II (normally-curing, medium-ground); the rest of components and processing sequence will be the same as for compositions 32-35. Compositions 36 and 37 will be used as warm masonry and finishing mortars, composition 38 -as semi-dry charge intended to mold structural heat-insulating unit hollow blocks, composition 39 -as light-concrete mix to fill hollow enclosing structures.

Example 4. Compositions of type (Alx* + A*x*) + (B2y* + B*y*).

Compositions 40-42 with mineral charge including filling aggregate made of sandy-expanded clay or sandy-crushed stone mix and lime-gypsum binding material will be prepared in gravity batch mixer. Used will be the following components: 2.5 -5 mm fraction expanded vermiculite having loosed density of 100 kg/rn3, Portland-blastfurnace cement ShPC 400, medium-fraction sand from granite sieve residue having Mk=2.5-2.0, 2.5 mm fraction expanded clay, crushed stone from 5 mm fraction gravel, powder lime having loose density of 420 kg/rn3, gypsum G-5 B II (normally-curing, medium-ground).

To prepare composition 40, the mixer will be loaded with 15 kg of sand, whilst constantly stirred loaded with 65 kg of expanded clay, supplemented with 40 kg of lime and 100 I of water, agitated during 1.5 minute, loaded with 80 kg of cement, supplemented with 10 kg of gypsum, 50 kg of expanded vermiculite to gradually be poured, supplemented with the rest of water and agitated during 1.5 -2 minutes. Composition 40 will be used as liquid mixture to fill cavities in partition blocks made of expanded clay concrete etc. Prepared in the similar manner will be compositions 41 and 42 to be respectively used to fill hollow wall sand-cement blocks and to mold structural heat-insulating blocks.

Compositions 43, 44 with mineral charge including filling agent made of sand-expanded clay or sand-crushed stone mix and lime-clayey binding material will be prepared in gravity batch mixer similarly to the preparation of compositions 40 -42. Clay LI-i will be used. The rest of components will be the same as those used in compositions 40 -42. Prepared compositions will be used as semi-dry charge to mold structural heat-insulating blocks.

Compositions 45, 46 with mineral charge including filling aggregate made of sand-expanded clay or sand-crushed stone mix plus binding material made of gypsum intermixed with clay will be prepared in gravity batch mixer in the similar manner as the preparation of compositions 40 -42. Used will be gypsum G-5 B II (normally-curing, medium-ground). The rest of components will be the same as for compositions 40 -42. The prepared compositions will be used as light concrete mixture to fill hollow enclosing structures.

Composition 47-49 with mineral charge including filling aggregate of expanded clay intermixed with crushed stone and binding material of lime intermixed with gypsum or lime intermixed with clay or gypsum intermixed with clay will be prepared in planetary mixer. Used will be the following components: 2.5 fraction expanded vermiculite, Portland cement 400-D20-PL (with additives of up to 20%, plasticized), medium-fraction river sand, 2.5 -5 mm fraction expanded clay, fraction 5 crushed dolomite stone, powder lime having loose density of 450 kg/rn3, gypsum G-5 B H (normally-curing, medium-ground), bentonite clay containing (mass percent): Si02 -57.i, A1203 -19.40, Fe203 -5.97, MgO -3.01, K20 -1.03 (Deposit Zyaryanskoye, Russia). Clay will preliminarily be intermixed with tempering water to obtain colloidal suspension that will be introduced into dry mix prior to introducing vermiculite. Then, the whole mix will be agitated to obtain homogeneous mass. The obtained compositions will respectively be used as concrete mix to fabricate structural heat-insulating bases, sealing compound and semi-dry charge for molded products.

Example 5. According to Prototype Compositions 50, 51 with mineral charge of calcined mica will be prepared in planetary mixer. Composition 50 includes: Portland cement PC 500-DO (2 parts by volume), 4 mm fraction expanded vermiculite KLU4W 4 having loose density of 110 kg/rn3 (4 parts by volume), 2.5 mm fraction calcined mica having loose density of 500 kg/rn3 (5 parts by volume) and water (2,6 parts by volume). Composition 51 includes: Portland cement PC 500-DO (2 parts by volume), 16 mm fraction expanded vermiculite having loose density of 90 kg/rn3 (6 parts by volume), 2.5 mm fraction calcined mica having loose density of 500 kg/rn3 (1 parts by volume), 50 % acrylic emulsion (0.2 parts by volume) and water (2.6 parts by volume). To prepare the compositions, the mixer will be loaded with expanded vermiculite and mica, whilst constantly stirring, the mixture will be wetted with water, supplemented with cement, the rest of water and emulsion and agitated during 2.5 -3 minutes to obtain homogeneous mass.

The above examples and Table 1 indicate that, as compared to the prototype, the proposed crude mix allows for preparing compositions having various consistencies from liquid mortars to semi-dry masses that could be used practically for the whole range of construction materials and products: in applying heat-, sound-insulating and fire protective coatings and plasters, filling hollow enclosing structures and individual blocks, manufacturing unit heat-insulating and structural heat-insulating blocks etc. Table 2-contained data show that, as compared to the prototype, the fabricated materials have lower mass specific gravity (volume weight) with high strength and low heat conductivity, which allows for reducing weight loads in building enclosing structures, foundations and flooring with the simultaneous enhancement of their heat-and energy-saving properties. According to estimates, e.g. to ensure heat transmission resistance as high as Ro=3.14 m2 C/W Central Russia) of walls containing equally strong materials of compositions 50 and 43 (mix according to the prototype and the proposed mix) and of compositions 51 and 27 (mix according to the prototype and the proposed mix), its thickness will amount to 0.97 m and 0.41 m and respectively 1.11 m and 0.35 m, which allows for reducing weight of each 1 m2 of wall more than by 4 times affecting no strength of the enclosing structure material, lower load on foundation, save costs of materials and structure as a whole.

Table 1

compositions for 1,000 kg of crude mix Camp Cement, Vermiculi Mineral charge (components), Water, ositio kg te, kg n No. kg Compositions of type Ax + By 1 80 50 (s)115+(l)15 740 2 80 150 (s) 245+(l) 175 350 3 150 200 (s)300 + (I) 50 300 4 250 210 (s)380+(l)40 120 250 210 (s)200+(l)220 120 6 100 80 (s) 150 + (g) 225 445 7 250 50 (s)115+(cl) 15 570 8 200 180 (xcl)350 + (I) 50 220 9 80 210 (xcl)185+(l)255 290 250 210 (xcl)380+(g) 40 120 11 220 150 (xcl) 250 + 25(d) 355 12 120 90 (cs) 200 + 120 (I) 470 13 80 50 (cs)320 + (I) 40 510 14 120 120 (Cs) 380 + (g) 40 340 250 100 (cs)300 + (ci) 30 320 Compositions of type (Alx* + A*x*) + By 16 80 50 [(s)40 + (xcl)70] +(l)20 740

Table 1 (continued)

17 100 100 [(s) 50 + (xci) 150] +(l)75 525 18 80 210 [(s)20 + (xci) 360] +(l)40 290 19 250 210 [(s)20 (xci)360] +(g)40 120 250 200 [(s) 100 + (xci) 100] (ci) 100 250 21 250 210 [(s)100 + (cs)120] +(i)50 270 22 120 100 [(s) 150 + (cs)150] + (g) 100 380 23 250 50 [(s)10 + (cs)110] +(ci)10 570 24 80 50 [(xci) 200 + (cs) 180] + (1)40 450 200 180 [(xci)250+(cs)120] +(l)50 200 26 150 150 [(xcl)300 (Cs) 70] + (g) 50 280 27 250 210 [(xci) 150 (Cs) 150] +(cl) 30 210 Compositions of type Ax + (B2y* + B*y*) 28 80 50 (s) 90 + [(I) 20 + (g)20] 740 29 125 105 (s) 250 + [(I) 100 + (g) 70] 350 80 50 (xci) 100 + [(I) 200 + (g) 40] 530 31 250 210 (cs) 300 + [(i) 60 (g) 60] 120 32 80 50 (s) 90+ [(I) 20 (ci) 20] 740 33 80 50 (xci) 150 + [(i) 200 + (ci) 40] 480 34 250 210 (cs) 300 + [(I) 60 + (ci) 60] 120 150 100 (s) 250 + [(i) 100 + (ci) 70] 330 36 80 50 (s)300 + [(g) 50 + (ci) 50] 470

Table 1 (continued)

37 80 150 (xci) 200 + [(g) 120 + (cl)80J 370 38 250 210 (cs) 300 + {(g) 100 + (ci) 20 1 120 39 150 100 (s) 50 + [(g) 95 + (ci) 35] 570 Compositions of type (Alx* + A*x*) + (B2y* + B*y*) 80 50 [(s)15 + (xci) 65] + [(1)40 (g)10] 740 41 80 50 {(s) 50 + (cs)150] + [(I) 180 +(g)30] 460 42 180 200 [(s) 150 + (cs)150] + [(1)100 +(g)20] 200 43 250 210 [(s) 100 + (xci) 150] + [(I) 120 +(ci) 120 50] _______ 44 200 150 [(s) 300 + (cs) 50] + [(I) 50 +(ci) 20] 230 125 105 [(s)30 + (xcl)100] [(g)50 +(cI)50] 540 46 80 210 [(s) 15 (cs)65] + [(g)40 +(ci)10] 580 47 250 50 [(xci)150 (cs)150] + [(I) 80 +(g) 40] 280 48 100 180 [(xci) 100 + (Cs) 80] + [(i) 50 +(cI) 30] 460 49 220 200 [(xci) 300 + (cs)50] + [(g) 50 +(ci)20] 160 Compositions according to prototype 50. 285 55 (cm) 320 340 51. 375 95 (cm) 85 445 Conventional signs: (s)-sand, (xcl)-expanded clay, (cs)-crushed stone, (I)-lime, (g)-gypsum, (cl)-clay, (cm)-calcined mica

Table 2

Properties of Materials Numbers of Dry samples compositions Mass specific Compressive Heat conductivity, Frost density, kg/m3 resistance, W/m K, resistance, MPa NLT cycles Compositions of type Ax + By 1,7 520, 720 1.5; 3.5 0.12; 0.20 15, 35 13 820 5.5 0.26 35 11,12,14, 540,530,735, 1.7; 1.6; 3.5; 0.11;O.12; 0.21; 15,15,35, 850 6.5 0.25 40 2,3,6 500,400,620 1.1; 1.0; 4.8 0.11; 0.09;0.18 15,10,20 9 507 2.1 0.11 15 4,5, 590,420, 2.0; 1.5; 0.14;0.10; 20,15, 8,10 600,460 3.3; 1.8 0.14; 0.11 30,15 Compositions of type (Alx* + A*x*) + By 16 430 0.8 0.10 15 23 860 6.5 0.28 45 17,24 595,550 3.5; 0.14; 0.13 25,20 18,20,2 1, 420,470,400, 0.8; 1.2;0.8; 0.8;0.1;0.09; 15, 20,15, 22,26 515,515 1.5; 1.6 0.12; 0.11 20, 20 19,25,27 440,440,475 1.9; 2.0; 2.6 0.1O;0.11;0.11 20,25,25

Table 2 (continued)

Compositions of type Ax + (B2y* + B*y*) 28,32 520,520 1.8; 1.8 0.12;0.12 20,20 29, 36,39 540,880,615 2.0; 6.3; 3.8 0.14; 0.28; 0.16 20,35,25 30,33,37 670,740,570 4.2; 4.6; 3.5 0.22; 0.25; 0.15 25,30,20 670 3.0 0.18 25 31,34,38 550,630,490 2.9; 3.7; 2.6 0.13; 0.17;0.11 20,25,20 Compositions of type (Ajx* + A*x*) + (B2..y* + B*y*) 430 0.8 0.10 15 41,45,46, 675,510,300, 3.7; 1.8; 0.8; 0.23;0.12;0.08; 25,20,10, 48 410 1. 5 0.10 15 44,47 770,655 4.5; 4.3 0.24;0.26 30,25 42,43,49 400,550,380 1.2; 2.2; 1.4 0.09;0.13;0.09 15,20,15 Compositions according to Prototype 945 2.2 0.31 20 51 1110 2.6 0.35 25 NB: Numbers of the compositions are grouped on the basis of the following principles: crude mix consistency (liquid, semi-thick, thick, semi-dry) and filling aggregate type (with sand and grains of expanded clay and/or crushed stone). E.g.: 1, 7 (liquid with sand), 13 (liquid with grains), 11,12, 14, 15 (semi-thick with grains), 2, 3, 6 (thick with sand), 19, 25, 27 (semi-dry with grains) etc.

Claims (1)

1. CLAIM

   Crude mix designed for the fabrication of construction materials and products containing cement, expanded vermiculite, mineral charge and water, and distinctive in that its mineral charge is represented by dry mix of one or two materials chosen out of Group I including sand, expanded clay, crushed stone and one or two materials chosen out of Group II including powder lime, gypsum, clay having the following relationship of components: for charge of any single material chosen out of Group I and any single material chosen out of Group II weight parts will respectively amount to 1.0 and 0.1 -1.5; for charge of any two materials chosen out of Group II weight parts will respectively amount to 0.95 -0.05 as for material I of Group I, and 0.1 -1.5 as for material of Group II; for charge of any single material chosen out of Group I and any two materials chosen out of Group H weight parts will respectively amount to 1.0 as from material of Group I, 1.9 -0.1 -as for material I of Group II, 0.1 -1.9 as from material II of Group II; for charge of any two materials chosen of Group I and any two materials chosen out of Group II weight parts will respectively amount to 0.95 -0.1 as for material I of Group I, 0.95 -0.05 -as for material II of Group I, 1.9 -0. 1 -as for material I of Group II, 0.1 -1.9 as for material II of Group II with the following relationship between the mix components (weight percent): Cement 8 -25 Vermiculite 5 -21 Mineral charge 13 -42 Water the rest.