JP2022530193A - 湿式鋳造スラグ系コンクリート製品の製造 - Google Patents
湿式鋳造スラグ系コンクリート製品の製造 Download PDFInfo
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- 229910002092 carbon dioxide Inorganic materials 0.000 claims abstract description 7
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 33
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 229910000831 Steel Inorganic materials 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 12
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- 229910052918 calcium silicate Inorganic materials 0.000 claims description 3
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 claims description 3
- 239000010962 carbon steel Substances 0.000 claims description 3
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- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 3
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- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 3
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- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 2
- 239000000292 calcium oxide Substances 0.000 description 2
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 2
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- JTJMJGYZQZDUJJ-UHFFFAOYSA-N phencyclidine Chemical class C1CCCCN1C1(C=2C=CC=CC=2)CCCCC1 JTJMJGYZQZDUJJ-UHFFFAOYSA-N 0.000 description 1
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- 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
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/08—Slag cements
- C04B28/082—Steelmaking slags; Converter slags
-
- 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
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
-
- 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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
-
- 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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
-
- 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
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
-
- 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
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
- B28B7/42—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for heating or cooling, e.g. steam jackets, by means of treating agents acting directly on the moulding material
-
- 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
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/08—Slag cements
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- 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
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/08—Slag cements
- C04B28/085—Slags from the production of specific alloys, e.g. ferrochrome slags
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- 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
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/02—Selection of the hardening environment
- C04B40/0231—Carbon dioxide hardening
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
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Abstract
Description
湿式鋳造スラグ系コンクリート56の製造における主な結合材は、好ましい実施形態では、鋼又はステンレス鋼の生産に由来するスラグ11である。また、亜鉛、鉄及び銅の生産による他の副産物材料をスラグ11として考えることができる。
湿式鋳造スラグ系コンクリート56の方法1は、非ゼロスランプコンクリート16の組成物を提供し、スラグ11及び任意の少なくとも1つの他の結合材13(スラグ系結合材14を提供する)と、骨材15と、化学混和剤17と、繊維19と、水5と、を含むがこれらに限定されない組成物のすべての成分を均一に混合10することから始まる。本発明で使用される湿式鋳造スラグ系コンクリート56の水対結合材比は、乾式鋳造又はゼロスランプコンクリートの含水量よりも高くすべきである。好ましい実施形態では、混合非ゼロスランプコンクリート16は、0.2、好ましくは0.25、好ましくは0.3、好ましくは0.35、好ましくは0.4、好ましくは0.45、好ましくは0.5、好ましくは0.55、好ましくは0.6又は好ましくは0.65よりも大きい第1の水対結合材重量比を有する。「水対スラグ系結合材重量比」及び「水対結合材重量比」という用語は同等のものである。
好ましい実施形態では、非ゼロスランプコンクリート16を鋳造する前に、鋳型を調製し、必要に応じて、炭素鋼、ステンレス鋼及び/又はFRP強化鉄筋などの強化材を鋳型内に配置する。鉄筋の直径は、5mm~60mmの範囲で変化し、耐力強度は100MPa~2100MPaの範囲であり得る。強化材は、規則及び規格に従って設計される。
生の調製済み非ゼロスランプコンクリート16は、適切な手段によって移され、従来技術の任意の既知の方法で調製された鋳型内で鋳造される。鋳型は、鋼、鉄、アルミニウム、プラスチック、FRP又は他の材料で作ることができる。鋳型は、脱型プロセス30を容易にするために、鋳造前に予め潤滑されるべきである。湿式鋳造コンクリート又はスラグ系中間体26は、内部又は外部の振動器によって、120秒以内で鋳型内に固められる。湿式鋳造コンクリート又はスラグ系中間体26は、鋳型内でプレス又は圧縮する必要はない。すなわち、好ましい実施形態におけるプロセスは、プレス又は圧縮を含まない。スラグ系中間体26は、水32の損失により、鋳型内で部分的に又は完全に凝結させることができる。
事前調整40ステップは、CO2養生50の前に、脱型中間体36(現在はスラグ系中間体26)の含水量を第3の水対結合材重量比までさらに減少させる。脱型中間体36を周囲温度及び湿度に保ち、自由水42を徐々に蒸発させることができる。脱型中間体36の蒸発速度は、温度、相対湿度、脱型中間体36の初期含水量、製品の表面積、及び鋳型が風に曝されている場合の空気流に依存する。脱型中間体36の事前調整ステップは、気密室、密閉空間チャンバ又は容器内で行うことができる。
(v)CO2活性化/養生50
Claims (18)
- 湿式鋳造スラグ系コンクリート製品の製造方法であって、前記方法は、
スラグ系結合材と、骨材と、水と、を提供する提供ステップと、
前記スラグ系結合材と、前記骨材と、前記水と、を混合して、0.2を超える第1の水対スラグ系結合材重量比を含む非ゼロスランプコンクリート組成物を製造する混合ステップと、
前記非ゼロスランプコンクリート組成物を鋳型に移すことにより、前記非ゼロスランプコンクリート組成物を鋳造する鋳造ステップと、
前記非ゼロスランプコンクリート組成物を前記鋳型内で凝結させて、前記第1の水対スラグ系結合材重量比よりも小さい第2の水対スラグ系結合材重量比を含むスラグ系中間体を製造する凝結ステップと、
前記スラグ系中間体を脱型して、脱型中間体を製造する脱型ステップと、
前記脱型中間体を事前調整して、前記第1の水対スラグ系結合材重量比よりも小さく、かつ前記第2の水対スラグ系結合材重量比よりも小さい第3の水対スラグ系結合材重量比を含む脱型事前調整済みスラグ系中間体を製造する事前調整ステップと、
前記脱型事前調整済みスラグ系中間体を二酸化炭素で養生して、前記湿式鋳造スラグ系コンクリート製品を製造する養生ステップと、を含む、方法。 - 前記非ゼロスランプコンクリート組成物の前記鋳造ステップが、プレス/圧縮を含まない、請求項1に記載の方法。
- 前記スラグ系結合材が、飛散灰、焼成頁岩、シリカヒューム、ゼオライト、GGBF(粉砕造粒高炉)スラグ、石灰石粉末、水硬性セメント及び非水硬性セメントからなる群から選択される少なくとも1つの他の結合材を含まないか、又はそれらと混合されたスラグである、請求項1又は2に記載の方法。
- 前記スラグが、製鋼スラグ、ステンレス製鋼スラグ、塩基性酸素転炉スラッジ、高炉スラッジ、亜鉛、鉄又は銅生産の副産物、及びこれらの組み合わせからなる群から選択される、請求項3に記載の方法。
- 前記鋳造ステップの前に前記鋳型に強化材を配置する強化ステップをさらに含む、請求項1~4のいずれか一項に記載の方法。
- 前記強化材が、炭素鋼、ステンレス鋼及び/又はFRP強化鉄筋である、請求項5に記載の方法。
- 前記スラグの累積ケイ酸カルシウム含有量が、少なくとも20重量%である、請求項1~6のいずれか一項に記載の方法。
- 前記事前調整ステップを実施して、前記湿式鋳造スラグ系コンクリートの体積の少なくとも1%の多孔度を増加させる、請求項1~7のいずれか一項に記載の方法。
- 前記非ゼロスランプコンクリート組成物が、5mm~250mmの範囲のスランプ値を有する、請求項1~8のいずれか一項に記載の方法。
- 前記非ゼロスランプコンクリート組成物が、0.7~1.0の範囲の生コンクリートの圧縮係数試験を有する、請求項1~9のいずれか一項に記載の方法。
- 前記スラグ系結合材が、還元製鋼スラグ、酸化製鋼スラグ、転炉製鋼スラグ、電気アーク炉(EAF)スラグ、塩基性酸素炉(BOF)スラグ、取鍋スラグ、高速冷却製鋼スラグ及び徐冷製鋼スラグ、並びにこれらの組み合わせからなる群から選択される製鋼スラグである、請求項1~10のいずれか一項に記載の方法。
- 前記湿式鋳造スラグ系コンクリート製品が、プレキャストの鉄筋及び非鉄筋コンクリートパイプ、ボックスカルバート、排水製品、舗装スラブ、床スラブ、交通障壁、壁、マンホール、擁壁、舗装、タイル及び屋根材からなる群から選択される、請求項1~11のいずれか一項に記載の方法。
- 前記湿式鋳造スラグ系コンクリートが、少なくとも5重量%のスラグ含有量を含む、請求項1~12のいずれか一項に記載の方法。
- 前記非ゼロスランプコンクリート組成物が、促進剤、遅延剤、粘度調整剤、空気混入剤、発泡剤、ASR(アルカリシリカ反応)阻害剤、洗い流し防止剤、防錆剤、収縮低減剤、コンクリート亀裂低減剤、可塑剤、超可塑剤、封止材、塗料、コーティング、減水剤、撥水剤、白華制御剤、ポリマー粉末、ポリマーラテックス及び加工性保持剤のうちの少なくとも1つをさらに含む、請求項1~13のいずれか一項に記載の方法。
- 前記非ゼロスランプコンクリート組成物が、セルロース繊維、ガラス繊維、マイクロ合成繊維、天然繊維、PP繊維、PVA繊維及び鋼繊維のうちの少なくとも1つをさらに含む、請求項1~14のいずれか一項に記載の方法。
- CO2養生が、追加の外部熱源及び/又はエネルギー源を含まない、請求項1~15のいずれか一項に記載の方法。
- 前記養生ステップは、少なくとも5体積%の濃度のCO2を含有するガスを用いて、チャンバ/密閉空間/容器/部屋内で行う、請求項1~16のいずれか一項に記載の方法。
- 前記脱型ステップは、前記脱型中間体が少なくとも0.01MPaの圧縮強度を有するときに行う、請求項1~17のいずれか一項に記載の方法。
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