JP4906843B2 - 軽量コンクリート組成物 - Google Patents
軽量コンクリート組成物 Download PDFInfo
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- JP4906843B2 JP4906843B2 JP2008503254A JP2008503254A JP4906843B2 JP 4906843 B2 JP4906843 B2 JP 4906843B2 JP 2008503254 A JP2008503254 A JP 2008503254A JP 2008503254 A JP2008503254 A JP 2008503254A JP 4906843 B2 JP4906843 B2 JP 4906843B2
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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
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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
- 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
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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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/009—Porous or hollow ceramic granular materials, e.g. microballoons
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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
- 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
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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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/0075—Uses not provided for elsewhere in C04B2111/00 for road construction
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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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/10—Compositions or ingredients thereof characterised by the absence or the very low content of a specific 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/40—Porous or lightweight materials
-
- 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
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
-
- 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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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Road Paving Structures (AREA)
Description
本出願は、米国仮特許出願第60/664,230号(2005年3月22日出願、発明の名称「Light Weight Concrete Composite Using EPS Beads」)、および同第60/686,858号(2005年6月2日出願、発明の名称「Lightweight Compositions and Materials」)の優先権の利益を主張するものである。
(1.発明の分野)
本発明は、一般に、建設・建築業で素材として有用である新たな組成物、材料、それらの使用方法、およびそれらの製造方法に向けられる。より具体的には、本発明の複合材は、高強度と、しばしば改善された断熱特性とを有する比較的軽量、伸縮可能、成形可能、注入可能である材料からの恩恵を享受する建設・建築での用途に使用され得る。
軽量セメント質材料、例えば、いわゆる軽量コンクリートの調製および使用の分野において、今までの業界で利用可能であった材料は、強度を有するが、軽量なコンクリート塊を達成するために、様々な構成成分の追加を、一般的に要求されてきた。このコンクリート塊は、構成成分の良好な均質性を有し、その塊の全体にわたって均一に結合される。
本発明は、軽量セメント質組成物を提供し、該軽量セメント質組成物は、10〜90体積%のセメント組成物と、平均粒径0.2mm〜8mm、バルク密度0.028g/cc(28kg/m 3 )〜0.64g/cc(640kg/m 3 )、アスペクト比1〜3を有する10〜90体積%の粒子と、10〜50体積%の砂および/または他の細骨材であって、該砂および/または細骨材の少なくとも一部分は、2未満の粗粒率を有する、砂および/または細骨材とを含み、使用される成分の合計は、100体積%を超えることがなく、該軽量セメント質組成物は、7日間にわたって固化された後に、ASTM C39に従って試験されたときに、少なくとも1700psi(11.72MPa)の圧縮強度を有する。
作業実施例以外において、あるいは他に特記しない限り、本明細書および請求項で使用される成分、反応条件など全ての数または表現は、全ての場合において、用語「約」によって、修正されるものとして、理解されるべきである。したがって、反対の指示が特にない限り、以下の明細書および添付の請求項に示される数字によるパラメータは、本発明が取得したいと望む所望の特性に依存して変動し得る概数値である。最低限でも、請求の範囲と均等の原則の適用限界を試みるものとしてではなく、各数字のパラメータは、報告される有効桁数の数字の観点で、通常の端数処理技術を適用して、解釈されるべきである。
SILVER(登録商標)である。
Nb=K/B3 (1)
Nbは、発泡ビーズの個数を表わす。
望ましい微細構造および/または形態は、明確なクラスに収まり得る。第一は、特別な界面を有する双連続(bicontinuous)または共連続(co−continuous)複合材であり、第二は、接続されたマトリックス内の特別な介在物を含む。双連続で、かつ単一に接続された微細構造の効果的な特性は、公知の最適クロス特性限度(cross−property bounds)によって、記載される。
固化される軽量コンクリート組成物の所望の密度特性および強度特性を同定することと、
該軽量コンクリート組成物に使用するために発泡されるべきポリマビーズのタイプ、サイズ、および密度を決定することと、
該ポリマビーズが発泡されるべきサイズおよび密度を決定することと、
該ポリマビーズを発泡して、発泡ポリマビーズを形成することと、
該発泡ポリマビーズをセメント質混合物の中に分散して、該軽量コンクリート組成物を形成することと、
該軽量コンクリート組成物を所望の形に固化することを可能にすることと
を含む。
・タイプIIIポルトランドセメント
・石工砂(mason sand)(バルク密度165pcf(2643kg/m 3 )、比重2.64、粗粒率=1.74)
・飲料水−雰囲気温度(約70°F/21℃)
・発泡ポリスチレン−M97BC、F271C、F271M、F271T(NOVA Chemicals Inc.(ペンシルバニア州Pittsburgh))
・EPS樹脂−1037C(NOVA Chemicals,Inc.)
・1/2インチ(1.27cm)膨張スレート(Carolina Stalite Company(ノースカロライナ州Salisbury)−バルク密度89.5pcf(1434.8kg/m 3 )、比重1.43)
を利用した。
・ASTM C470−コンクリート試験シリンダを垂直に形成するためのモールドに対する標準仕様
・ASTM C192−実験室でコンクリート試験片を作成および養生するための標準実施
・ASTM C330−構造用コンクリート向けの軽量骨材に対する標準仕様
・ASTM C511−水硬性セメントおよびコンクリートの試験に使用される混合室、湿潤キャビネット、湿潤室、および水貯蔵タンクに対する標準仕様
・ASTM C143−水硬性セメントコンクリートのスランプに対する標準試験方法
・ASTM C1231−硬化コンクリートシリンダの圧縮強度の決定における未結合キャップ(Unbonded Cap)の使用に対する標準実施
・ASTM C39−シリンダコンクリート片の圧縮強度に対する標準試験方法
に従った。
未発泡ビーズ形状のポリスチレン(M97BC−0.65mm、F271T−0.4mm、およびF271M−0.33mm)を事前膨張して、以下の表に示されるような異なる密度のEPSフォーム(プレパフ)粒子を得た。
未発泡ビーズ形状のポリスチレン(0.65mm、0.4mm、および0.33mm)を事前膨張させて、以下の表に示されるようなバルク密度2lb/ft3 (32.04kg/m 3 )を有するプレパフ粒子を得た。これらのプレパフ粒子を3.5立方フィート(0.09905m 3 )ドラムミキサ内で調合して、LWC組成物を得た。このドラムミキサは、46.5重量%(25.3体積%)のポルトランドセメント、16.3重量%(26.3体積%)の水、および1.2重量%(26.4体積%)プレパフ粒子を含む。この結果得られたLWC組成物は、90lb/ft3 (1442kg/m 3 )のコンクリート密度を有した。平均圧縮強度(7日間破断試験で、ASTM C39に従って決定)は、以下の表に示される。
プレパフ粒子密度はまた、全体のコンクリート密度にも影響を及ぼすので、EPS密度を変更することは、EPS装填レベルの変更が必要であり、それによって、一定のコンクリート密度を維持することができる。この関係は、プレパフ粒子の総量が、粒子を取り囲むコンクリートマトリックスの強度を低下させるほど大きくない限り維持される。プレパフ粒子密度と装填レベルとの間の関係は、全体のコンクリート密度を制御しながら、コンクリート強度を最適化すための追加の機会を提供する。
未発泡ビーズ形状のポリスチレン(0.65mm)を事前膨張して、プレパフ粒子を得た。これらのプレパフ粒子は、以下の表に示されるように、1.1lb/ft3 (17.62kg/m 3 )のバルク密度を有する。これらのプレパフ粒子を、3.5立方フィート(0.09905m 3 )ドラムミキサ内で調合して、以下の表に示される成分を含むLWC組成物を得た。
未発泡ビーズ形状のポリスチレン(0.65mm)を事前膨張して、以下の表に示されるような様々な密度を有するプレパフ粒子を得た。これらのプレパフ粒子を、3.5立方フィート(0.09905m 3 )ドラムミキサ内で調合して、以下の表に示される成分を含むLWC組成物を得た。
未発泡ビーズ形状のポリスチレン(0.65mm)を事前膨張して、以下の表に示されるような様々な密度を有するプレパフ粒子を得た。これらのプレパフ粒子を、3.5立方フィート(0.09905m 3 )ドラムミキサ内で調合して、以下の表に示される成分を含むLWC組成物を得た。
未発泡ビーズ形状のポリスチレン(0.65mm)を事前膨張して、以下の表に示されるような様々な密度を有するプレパフ粒子を得た。これらのプレパフ粒子を、3.5立方フィート(0.09905m 3 )ドラムミキサ内で調合して、以下の表に示される成分を含むLWC組成物を得た。
以下の実施例は、本発明のプレパフ粒子と組み合わせて、骨材としての膨張スレートの使用を示す。未発泡ビーズ形状のポリスチレンを事前膨張して、以下の表に示されるような様々な密度を有するプレパフ粒子を得た。これらのプレパフ粒子を、3.5立方フィート(0.09905m 3 )ドラムミキサ内で調合して、以下の表に示される成分を含むLWC組成物を得た。
以下の実施例は、本発明のプレパフ粒子と組み合わせて使用された骨材として、膨張スレートの使用を示す。未発泡ビーズ形状のポリスチレンを事前膨張して、以下の表に示されるような様々な密度を有するプレパフ粒子を得た。これらのプレパフ粒子を、3.5立方フィート(0.09905m 3 )ドラムミキサ内で調合して、以下の表に示される成分を含むLWC組成物を得た。
以下の表の実施例XおよびYに従って調製された調合物を型に注入し、24時間にわたって、その調合物を固化することが可能になるようにして、1フィート(30.48cm)四方、4インチ(10.16cm)厚のコンクリート形状を作成した。
実施例XおよびYの調合物を型に注入し、24時間にわたって、その調合物を固化することが可能になるようにして、1フィート(30.48cm)四方、4インチ(10.16cm)厚のコンクリート形状を作成した。7日後に、1フィート(30.48cm)四方で、1/2インチ(1.27cm)シートの標準乾式壁シートを形成されたコンクリートに、標準1 3/4インチ(4.445cm)ドライウォールネジを用いて、直接締め付けた。最低1インチ(2.54cm)のネジの貫通が、十分な締め付けをするために要求された。その結果が、以下の表に示される。
実施例XおよびYの調合物を型に注入し、24時間にわたって、その調合物を固化することが可能になるようにして、2フィート(60.96cm)四方、4インチ(10.16cm)厚のコンクリート形状を作成した。7日後に、3フィート(91.44cm)長、2”×4”(5.08cm×10.16cm)のスタッドを、標準16d釘を用いて、形成されたコンクリートに、直接締め付けた。最低2インチ(5.08cm)の釘の貫通が、十分な締め付けをするために要求された。その結果が、以下の表に示される。
追加の骨材を含まないコンクリートを、以下の表に示される成分を用いて、作成した。
骨材として、膨張スレートを含むコンクリートを、以下の表に示される成分を用いて作成した。
未発泡EPS(1037C)を含み、追加の骨材を含まないコンクリートを、以下の表に示される成分を用いて作成した。
1.2lb/ft3 (19.22kg/m 3 )に発泡されたF271T、1.3lb/ft3 (20.83kg/m 3 )に発泡されたF271C、および1.5lb/ft3 (24.03kg/m 3 )に発泡されたM97BCを走査電子顕微鏡(SEM)を用いて評価した。それぞれの表面および内部セルが、図20および図21(F271T)、図22および図23(F271C)、ならびに図24および図25(M97BC)に、それぞれ示される。
この実施例は、この軽量コンクリート組成物で締め具の使用と、その関連する引抜強度を示す。この評価を使用して、この軽量コンクリート(約90pcf(1442kg/m 3 ))に直接挿入されたネジの負荷能力を、通常重量である従来の軽量コンクリートに挿入された従来のコンクリート締め具と比較した。
この実施例は、本発明に従う軽量コンクリート組成物において、種々の砂のタイプの使用を示す。
Claims (18)
- 10〜90体積%のセメント組成物と、
平均粒径0.3mm〜2.5mm、バルク密度28.0kg/m3〜160kg/m3 を有する10〜90体積%の発泡ポリスチレン粒子と、
10〜50体積%の砂および/または他の細骨材と
を含む軽量セメント質組成物であって、
該砂および/または細骨材の少なくとも50体積%は、2未満の粗粒率を有する、軽量セメント質組成物。 - 前記発泡ポリスチレン粒子は、スムーズな外側層を有する、請求項1に記載の軽量セメント質組成物。
- 前記発泡ポリスチレン粒子は、少なくとも0.15μmの内部セル壁厚さを有する発泡ポリスチレン粒子を含む、請求項1に記載の軽量セメント質組成物。
- 前記発泡ポリスチレン粒子は、0.2mm〜1mmの非発泡平均樹脂粒子サイズを有するポリスチレンビーズを発泡することによって、調製された発泡ポリスチレン粒子を含む、請求項1に記載の軽量セメント質組成物。
- 前記発泡ポリスチレン粒子は、0.5mm〜2.5mmの平均粒子サイズを有する発泡ポリスチレン粒子を含む、請求項1に記載の軽量セメント質組成物。
- 前記軽量セメント質組成物を安定化する湿潤剤も分散剤も含まない、請求項1に記載の軽量セメント質組成物。
- 前記セメント組成物は、水硬性セメント組成物である、請求項1に記載の軽量セメント質組成物。
- 前記水硬性セメントは、ポルトランドセメント、ポゾランセメント、石膏セメント、石膏組成物、アルミナセメント、マグネシアセメント、およびスラグセメントからなるグループから選択される1つ以上の材料を含む、請求項7に記載の軽量セメント質組成物。
- 前記セメント質混合物は、粗骨材、可塑剤、および/または繊維をさらに含む、請求項1に記載の軽量セメント質組成物。
- 前記繊維は、ガラス繊維、シリコンカーバイド、アラミド繊維、ポリエステル、炭素繊維、複合繊維、繊維ガラス、該繊維の組み合わせ、該繊維を含む織物、および該繊維の組み合わせを含む織物からなるグループから選択される、請求項9に記載の軽量セメント質組成物。
- 前記粗骨材は、石、礫、高炉スラグ微粉末、フライアッシュ、ガラス、シリカ、膨張スレート、粘土;軽石、パーライト、バーミキュライト、スコリア、珪藻土、膨張ケツ岩、膨張粘土、膨張スラグ、フュームドシリカ、ペレット化骨材、成形フライアッシュ、凝灰岩、マクロライト、スレート、膨張高炉スラグ、焼結フライアッシュ、石炭ガラ、およびこれらの組み合わせからなるグループから選択される、請求項9に記載の軽量セメント質組成物。
- 641kg/m3〜2080kg/m3の密度を有する、請求項1に記載の軽量セメント質組成物。
- 請求項1に記載の軽量セメント質組成物を含む、路床。
- 建造物の形の型に入れられ、固化された、請求項1に記載の軽量セメント質組成物。
- コンクリートブロックユニットの形に、固化された、請求項1に記載の軽量セメント質組成物。
- 請求項1に記載の組成物を含む、プレキャストおよび/またはプレストレスされた建造物。
- 建造物パネルの形に、固化された、請求項1に記載の軽量セメント質組成物。
- タイプIIIのポルトランドセメントを含む10〜60体積%のセメント組成物と、
平均粒径0.75mm〜2.5mm、およびバルク密度28kg/m3〜160kg/m3 を有する20〜40体積%の発泡ポリスチレン粒子と、
15〜35体積%の砂および/または他の細骨材であって、該砂および/または細骨材の少なくとも50体積%は、2未満の粗粒率を有する、砂および/または他の細骨材と、
5〜15体積%の粗骨材と、
消泡剤、防水剤、分散剤、固化促進剤、固化遅延剤、可塑剤、超可塑剤、凍結温度低下剤、接着改善剤、着色剤、およびこれらの組み合わせのうちから選択される1つ以上の0.1〜1体積%の添加剤と
を含む、請求項1に記載の軽量コンクリート組成物。
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KR101187320B1 (ko) | 2012-06-19 | 2012-10-02 | 한대근 | 탄소원 첨가제를 포함하는 건축외장재용 노출 콘크리트 패널 및 이의 제조방법 |
KR20170127155A (ko) * | 2016-05-11 | 2017-11-21 | 경기대학교 산학협력단 | 내염해성 해양용 경량 콘크리트 조성물 |
KR101953151B1 (ko) | 2016-05-11 | 2019-02-28 | 경기대학교 산학협력단 | 내염해성 해양용 경량 콘크리트 조성물 |
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