NO763003L - FILLER FOR BUILDING MASSES, PAINTS AND THE LIKE. - Google Patents

Description

The invention relates to a filler for improving the mechanical wear resistance and/or heat resistance, in particular fire safety and/or temperature change resistance and/or thermal insulation and/or sound insulation and/or electrical insulation properties and/or workability for masses, in particular building masses and/or paints and the like.

Such fillers are added to specific materials and especially building materials to achieve or improve the above properties. To improve the specified properties, among other things, asbestos fibres, rock wool, glass wool, perlite, vermiculite, finely ground pumice stone, fireclay, fireclay flour, slag sand, quartz sand, sintered corundum, sintered dolomite, clay, dolomite-

dust, plaster, sawdust, cork flour and others. These substances fulfill

however, the above requirements only partially or incompletely or make production or workability difficult for the prepared masses. Some of the substances mentioned are expensive or can only be obtained in insufficient quantities and others, e.g. asbestos is so harmful to health that the compound should preferably not be used or is prohibited.

On the other hand, various chemical-technical processes and manufacturing methods create dusty products that have not yet found any reasonable use, because they cannot be recycled in the process in question. These products cause significant costs because they have to be stored in a landfill. This applies in particular to dusty components in the production of silicon or ferrosilicon which, due to their low specific gravity and the resulting large volume, take up a lot of space and therefore cause large waste costs or have to be briquetted using expensive methods.

The task is solved according to the invention by means of a filler which consists of dust-shaped products from the electrothermal production of ferrosilicon and/or silicon and predominantly contains amorphous, smoke-shaped SiC^-

The filler according to the invention is formed by electrothermal processes in the temperature range 1500 to 3000°C and has as a basic compound smoky amorphous SiC^ (approx. 82-95%), and also certain amounts of crystalline quartz (approx. 5-18%). X-ray examinations have shown that, with the exception of the relatively low proportion of quartz, the dust can be described as X-ray amorphous. Furthermore, the filler may contain small amounts of iron oxides and/or oxides of calcium and magnesium as well as carbon. The volumetric weight is approx. o.25 to 0.5 g/ml and the grain size distribution is such that 95% of the material has a grain size below 50 p.

The filler according to the invention is cheap and available in sufficient quantities. Surprisingly, the filler has properties that can be used for a wide variety of purposes,

and in particular for improving the mechanical strength and/or heat resistance, in particular the fire safety and/or temperature change resistance and/or thermal insulation and/or sound insulation and/or electrical insulating ability and/or workability for masses which are in particular building masses and/or paints and the like .

Preferably, the filler according to the invention is suitable for fire-retardant or fire-resistant mass, in particular a sprayable or stampable mass for building purposes, consisting of a binder, a fire-resistant or fire-retardant material and possibly other fillers.

Such refractory or fire-reducing or fire-proof masses which, according to the state of the art, consist of a mixture of cement and asbestos fibers are e.g. sprayed on steel beams to protect them from fire. It is true that fire resistance is achieved with these masses, but they are very expensive.

If, according to the invention, a fire-retardant or refractory mass containing the proposed filler is used, a better fire resistance is achieved significantly cheaper. The mass according to the invention has a higher thermal insulation ability which is at least partly due to the low density and the large specific volume of the dust-shaped products as well as a high wear resistance.

You can improve the mass's properties and especially its thermal insulation ability when you mix in glass or stone wool waste, e.g. from the production of insulating mats. The mass according to the invention also has good adhesiveness and great firmness at low volume, particularly when wetting or precipitating agents and/or similar substances are added.

Since the dusty products are in oxide form, chemical and physical reactions with other components of the fire-resistant mass are promoted and, when exposed to heat, shrinkage of the mass with the following crack formations is avoided or reduced, so that the filler has the effect of improving the thermal properties of the mass with increasing temperature.

Finally, the pulp can be added to other substances

with fire-retardant properties, in particular waste products formed by desulphurisation of flue gases, predominantly or exclusively containing CaS04.

The compound according to the invention is suitable both as a spraying compound and a tamping compound for use on construction sites in general, particularly for steel structures above ground, for insulation and protection of steel beams and within the steel industry in coking plants or foundries.

The mass was examined by an experiment. One used

a steel profile (profile HEB 220) with a length of 3600 mm with foot

plates welded on above and below and loaded with 133 tons, after a protective layer of a refractory mass of stone wool, Portland cement and silicon dioxide had been applied to the steel beam in a thickness of 2 3 mm, and the beam was exposed for a length of

3100 mm for temperatures that within 1.5 hours rose from 8°C

to 980°C. The beam showed no reduction in load-bearing capacity. The protective layer shrank during this time to an average thickness of 16 mm.

Comparison tests were carried out with marketed asbestos-containing spray compounds. In order to achieve fire protection in fire safety class F 90 (West German), 10 kg/m 2 of the specified asbestos-containing spray compound was required, but only 7 kg/m 2 of the compound according to the invention. The pulp according to the invention contained approx. 60% stone wool, 20% cement and 20% fillers. For testing the mass, per 25 kg dry matter 15 liters of water, added 75 ml "Lensodel", a surfactant based on ethylene oxide condensate. The layer thickness to achieve fire safety compound F 90 was approx. 60 mm joint mass consisting of 60% stone wool, 20% perlite and 20% cement. For the mass according to the invention with the composition stated above, only a layer thickness of approx. 5 mm, and only because such thin layers cannot be applied evenly with certainty, a layer thickness of approx. 15 mm. The above-mentioned composition of the mass can be changed within wide limits, depending on the mechanical and thermal requirements, and other known substances can be added, especially those that have heat-insulating properties, e.g. perlite.

Another preferred area of application for filler according to the invention is building boards. It is known to produce ceiling panels, partitions, doors, etc. of material plates, where the base material e.g. can be a chipboard or hard fiber board, which is sprayed with refractory materials. The production of plates according to this method is, however, very expensive. The same applies to slabs of concrete, plaster or the like, when they are to be made fireproof.

According to the invention, the heat resistance and especially the fire safety of such building boards is significantly improved when the fire-resistant mass described above is used as a base mixture for the building boards, especially concrete boards and chipboards.

Preferably, such a plate consists of a particularly flame-resistant cloth-shaped material of polymer or metal wire, which is reinforced with a sealing layer of paper or thin plastic foil, applied with a single-sided or double-sided coating of the above-mentioned refractory mass. The production of building boards is simplified when, for example, the wire cloth, which is sealed with reinforcement, is pulled off a roller and the refractory compound is applied to one or both sides by rolling, tamping or spraying. The composition of the mass can be changed according to the mechanical and thermal requirements.

It is also possible to produce a building board, in particular a fireproof or sound-absorbing board or mat, in that the inner core consists of pressed stone wool or glass wool which is provided with an adhesive and protective layer of the filler according to the invention, a granule or flour of stone material and a binding agent . Such a plate, which can also be flexible, can be cut to size as desired on site. The coating, which is also possibly elastic, and which has lacquer-like properties, can e.g. finely ground silica, marble or quartz or dolomite is added and colored with dyes. Such a plate or mat has a high bending capacity and provides sufficient fire protection and sound insulation.

Advantageously, the filler according to the invention can also be used as an additive to a protective layer for refractory stones. Until now, refractory stones have been provided with an insulating layer of e.g. water-repellent coating, for example paraffin coating, plastic covering and the like, which are intended to keep the stones dry until they can be built into the firebox or sintered. However, these insulating layers are not suitable because, when walled in the boiler room after melting down the layers and before sintering the stones, they leave gaps or joints which lead to the stones being destroyed or falling out prematurely. Moreover, these layers only protect to a limited extent against the absorption of moisture, so that the stones already after 4 -

6 weeks falling apart due to moisture absorption.

In order to prevent moisture absorption between the manufacture and installation of the stones, and at the same time to guarantee sintering, it is suggested to use a protective layer for the refractory stones that comprise. an organic binder and the same basic mixture used for the production of the stones as well as filler according to the invention. The protective layer, which preferably has a lower melting point than the stones themselves, thereby favors the sintering process and guarantees during the melting phase a flow transition between the material components in the stone and the material between the stones. You get a hygroscopic protective look with a sinter transition.

A procedure for applying this protective grout, whereby the base mix for ±ein is poured into a mold, possibly pressed and temperature-treated, is characterized by the base mix and/or the stone being sprayed onto the protective layer before and/or after pressing. protective

the layer can be applied to the mold as a spray or molding compound and then the base mixture that forms the stone can be filled into the mold. Alternatively or in combination, the stone can be sprayed with a protective layer before annealing or temperature treatment.

The filler according to the invention is suitable

further for the production of refractory concrete, which in particular

langes for the construction of high-rise buildings. In order to achieve an economical production without loss of firmness for the concrete in question, it is suggested that the concrete be added with filler according to the invention. By correspondingly mixing the filler in concrete, fire safety classes of e.g. F 90, F 120 or F 240. The amount of filler in the concrete can be between 5 and 50%.

Furthermore, the concrete may contain other heat-resistant additives such as stone wool. If the concrete is to be exposed to very high temperatures, Portland cement is less suitable as a hydraulic binder. The special binders that have hitherto been used for the production of refractory concrete, such as aluminum phosphate, aluminum sulphate and refractory clay, can be omitted.

Experiments have shown that concrete according to the invention can withstand a temperature of approx. 12 00°C for several hours.

Another preferred area of application for filler according to the invention is foundry technology. In the foundries, for the production of cores and outer shells sand is often used which is surrounded by phenolic resins. By . the casting produces harmful fumes, e.g. formaldehyde, f.enol, ammonia and other harmful substances. These vapors must be extracted and cleaned by expensive processes.

This can be avoided by using, according to the invention, a refractory casting sand which consists of a mixture of fine quartz-containing sand and filler according to the invention. The mixing ratio is set according to the size of the molds and cores. You can use binders that are not harmful to the environment, e.g. cement.

A further preferred area of application for the filler according to the invention is wear-resistant and high-temperature-resistant emery compounds. It is known to add fine quartz-containing powder to emery compounds to make the compound temperature and abrasion resistant. A significant improvement in high temperature and abrasion resistance is achieved with an emery compound to which fillers according to the invention have been added. This new emery compound has a temperature resistance of approx. 2000°C. With corresponding mixing conditions, the temperature stability can be set to between 1000 and 2000°C. Mixed with corundum and similar substances, the emery mass according to the invention can be used for technically highly qualified purposes. The filler can also be advantageously used to improve the insulating ability of electrical fittings, especially junction boxes, fuses and the like, when the material used for these fittings is added to the filler during manufacture.

A significant problem in plastics technology consists in making plastics heat-resistant in an economical way. Plastic materials are usually unstable in the range 80 - 120°C, i.e. that within this range they change their structure and are no longer durable. Polymer materials which are described as heat-resistant are, incidentally, only slightly erosion-resistant.

In order to improve the heat resistance and mechanical wear resistance of the plastic material, it is suggested that the relevant plastic products are mixed with filler according to the invention in the base material or during a later processing process, so that a final material containing this filler is obtained. Such a composite polymer material is durable up to 200°C and higher, and has significantly improved mechanical wear resistance and erosion resistance. The amount of filler added to the plastic material is adjusted according to the requirements, and can be up to 50% of the total weight.

The properties of foamed plastic materials can also be improved by adding the relevant filler.

A polyurethane foam added between 10 and 50% of the filler is

largely flame-resistant and self-extinguishing. By adding crystalline SiO2, these results cannot be achieved.

A further important area of application for the filler according to the invention is paints, particularly for resistant and insulating coatings on building elements and building parts. For insulation against wear and corrosion and against fire and oil spills, varnishes or paints are used which are made from different base materials. As a rule, the paints contain organic compounds such as phenolic resins, polyurethanes and the like. The paint's resistance to wear and corrosion, as well as its fire safety and resistance to oil spills, is too poor.

The properties of such coatings, particularly resistant and insulating coatings on building elements and the like, are improved when fillers according to the invention are added to the paints. This not only improves the various fastness properties of the paints, but also achieves other uses for such paints. Compared to rubber or plastic compounds, fire safety and wear resistance are significantly increased. You can thus achieve temperature resistance of well over 500°C with paint according to the invention. Furthermore, the paint can be produced at a considerably lower price, which, by comparison, is up to 80% below comparable paint types. Depending on the requirements, the amount of filler can be up to 50%.

For varnishes, especially synthetic resin varnishes, are

it is known to improve their properties by adding boryl phosphate and/or boron nitrogen and/or urea. Metal oxides can also be added. A further substantial improvement of the heat resistance and the mechanical properties, in particular the wear resistance, is achieved by adding the filler in question in an amount of up to 50%.

To make the varnish not only flame-resistant and heat-resistant, but at the same time prepare the surface against growth and scale formation, e.g. on shipboards, it is suggested to add to the varnish so-called coffee wax, which is the residue of coffee extraction.

The erosion resistance of the lacquers can be further increased by adding metal oxide-containing dust from steel production to the lacquer in addition to the filler according to the invention.

Finally, the filler can be advantageously used in the area of sound dampening and sound insulation, especially on parts in transport means, machines, appliances and the like, which act as a resonance base, when applying paint layers or porous layers. By adding plasticizers and the desired filling materials, the desired sound insulation is achieved for the plastering compounds, which are often based on salt. Both the plasticizers mentioned and the usual filling materials consist of organic substances which are flammable. In extreme temperature conditions, the coating compounds can also detach from the coated parts, because both the base material and the plasticizer either become liquid or brittle.

To avoid this, a fire-proof and corrosion-resistant mass for sound insulation, containing the appropriate filler, is suggested. Due to the filler's large surface area and amorphous structure as well as its high temperature resistance, the mass achieves the desired sound dampening properties. Man-found e.g. that a mixture of asphalt and filler according to the invention without the addition of plasticizer gave the same soundproofing effect as known soundproofing paints. Another advantage is that the adhesion is significantly increased by the addition of filler so that the mass is also suitable for sound dampening, e.g. as underfloor protection in cars or to protect frame profiles that are particularly exposed to water and/or road salt. The amount of filler can go

up to 50% of the total weight.

Furthermore, the filler can be used with advantage

for the production of refractory or highly refractory masses for industrial furnaces and the metallurgical industry. These rammed masses can contain approx. 35% and spraying materials up to approx. 50% filler. The compounds show low shrinkage, a low lower sintering temperature, high refractoriness, high adhesion to the substrate, high surface hardness and good elasticity. A mass produced by

30% chamotte (grit 80% 0 - 0.5 mm), 30% sand (0 to 0.5 mm) 10% clay-melting cement and 30% of available filler, as well as 20% water as spray compound suitable for repairing chambers -walls in coke ovens. Due to the large temperature differences that go from approx. 800°C near the door to approx. 1200°C in the middle of the chamber, it has been necessary to use several different repair compounds adapted to the different temperature ranges. The present mass, on the other hand, can be used in the entire temperature range of the coke oven wall. After spraying on the compound, a completely crack-free covering was obtained which adhered securely to the wall and showed a very high mechanical resistance and durability.

A particular advantage is achieved by the addition

of alkaline components is eliminated when the filler is used in refractory and highly refractory masses. With the previously known refractory and highly refractory masses, it was necessary to add alkalis such as sodium silicate in order for the mass to achieve sufficient adhesion to refractory stones. However, one had to include in the purchase a reduction of the softening point for the stones, and damage to the stones.

Stamping compound is used for repairing coke oven doors. Such a tamping compound can consist of 15% sand (0 - 0.5 mm), 50% chamotte B (0-4 mm), 15% clay-fused cement and 20% filler. The stamping compound has a temperature resistance of approx. 1100°C.

For foundries, a tamping compound consisting of 66% sand (grain size 0-4 mm), 5% chamotte A, 7% Portland cement 450 and 22% filler is suitable. This mass has a temperature resistance of 1550°C.

For all of the aforementioned proposed mixtures, for which control tests have been carried out with finely ground crystalline silicon dioxide, it turned out that in no case could one achieve as good results as with silicon dioxide filler in amorphous form.

Claims (38)

1. Filler for improving the properties of building compounds, paints and the like, in particular mechanical wear resistance and/or heat resistance, particularly fire resistance, and/or temperature change resistance and/or thermal insulation and/or electrical insulation and/or workability, characterized in that the filler consists of dust-shaped products containing amorphous, smoky SiC^ originating from the electrothermal production of ferrosilicon and/or silicon. 2. Filler as stated in claim 1, characterized in that it contains over 82% X-ray amorphous sio2. 3. Filler as specified in claim 2, characterized in that it consists of approx. 82 -95% X-ray amorphous SiC^, approx. 5-18% crystalline quartz, less than 2.5% Fe20^, CaO, MgO and/or C, has a bulk density of 0.25 to 0.5 m/ml and has a grain size such that 95% of the filler is below 50 u. 4. Refractory mass, especially spray mass or tamping mass for building purposes, consisting of a binder, a fire-retardant material and possibly fillers, characterized in that the masses contain fillers according to one or more of requirements 1 to 3. 5. Mass as specified in claim 4, characterized by the addition of glass wool or stone wool waste from the manufacture of insulating mats. 6. Mass as stated in claim 4 or 5, characterized by the addition of wetting agents and/or felling agents. 7. Mass as specified in one or more of claims 4 to 6, characterized in that waste products from the desulphurisation of flue gases are also used, containing predominantly or exclusively CaSO^. 8. Mass as specified in claims 4 to 7, characterized in that it is used as a coating agent on steel beams or other steel elements. 9. Mass as specified in one or more of claims 4 to 7, characterized in that it is used as a base mix for building boards, especially concrete boards and chipboards. 10. Mass as specified in one or more of claims 4 to 9, characterized in that it contains 60% rock wool, 20% cement and 20% filler. 11. Building board as stated in claim 9 or 10, characterized by particularly flame-resistant braiding of plastic or metal wire, coated with a sealing layer of paper or thin plastic foil, and coated on one or both sides with mass according to claim 9. 12. Building board, especially fireproof and sound-absorbing board or mat according to claim 9 or 10, characterized by the wood inner core of pressed stone wool and/or glass wool and an adhesive and protective layer consisting of filler according to claim 1 to 3, a granulate or flour of stone material and a binder. 13. Protective layer for refractory stones, characterized by the fact that it consists of an organic binder and the same basic mixture that is used for the manufacture of the stones as well as filler as stated in one or more of claims 1 to 3. 14. Method for applying a protective layer according to claim 13, whereby the base mixture for the stone is poured into a mold, possibly pressed and temperature-treated, characterized in that the base mixture and/or the stone is sprayed onto the protective layer before and/or after pressing. 15. Method as stated in claim 14, characterized in that the protective layer is first applied as a spray or molding compound, and the base mixture for the stone is then filled into the mold. 16. Method as stated in claim 13 or 14, characterized in that the stone is sprayed with the protective clay layer before temperature treatment. 17. Fireproof concrete, characterized in that it contains filler according to requirements 1 to 3. 18. Beong as specified in claim 17, characterized by the addition of stone wool. 19. Concrete as specified in claim 17 or 18, characterized by a content of 5 to 50% filler. 20. Refractory foundry sand, characterized in that it consists of a mixture of fine quartz-containing sand, filler according to claims 1 to 3 and a binder. 21. High-temperature and wear-resistant emery compound, characterized in that it contains filler according to claims 1 to 3. 22. Insulating material for electrical fittings, in particular for fuses, characterized in that filler has been added to improve the insulating ability in accordance with one or more of requirements 1 to 3. 23. Polymer material, characterized in that filler has been added in accordance with one or more of claims 1 to 3 to improve the heat resistance and/or mechanical properties. 24. Plastic material according to claim 23, characterized by a filler content of up to 50%. 25. Polymer material as stated in claim 23 or 24, characterized in that it is foamed. 26. Paint based on organic compounds such as phenolic resins, polyurethanes and the like, especially for the application of durable and insulating protective layers on building elements, characterized by the content of filler according to claims 1 to 3. 27. Synthetic resin lacquer, characterized in that it contains filler according to claims 1 to 3. 28. Synthetic resin varnish as specified in claim 27, characterized by the content of boryl phosphate. 29. Synthetic resin varnish as stated in claim 27 or 28, characterized by content of boron nitrogen.. 30. Synthetic resin varnish as specified in one or more of claims 27 to 29, characterized by the content of urea. 31. Synthetic resin varnish as specified in one or more of claims 27 to 30, characterized by the content of dust-shaped metal oxides from steel production. 32. Synthetic resin varnish as specified in one or more of claims 27 to 31, characterized by the content of coffee wax in the form of residues from coffee extraction. 33. Synthetic resin varnish as specified in one or more of claims 27 to 32, characterized by the content of borax. 34. Refractory and corrosion-resistant mass for sound attenuation, characterized by the content of filler according to one or more of the requirements 1 to 3. 35. Refractory or highly refractory spray compound or tamping compound for industrial furnaces and metallurgical containers, characterized in that it contains filler according to one or more of claims 1 to 3. 36. Spray compound as specified in claim 35, particularly for walls in coke oven chambers, characterized in that they consist of 30% fireclay, 30% sand, 10% clay-melt cement and 30% filler. 37. Tamping compound as stated in claim 35, especially for coke oven doors, characterized in that they consist of 15% sand, 50% fireclay B, 15% clay-melting cement and 20% filler. 38. Tamping compound as specified in claim 35, particularly for metallurgical containers, characterized in that they consist of 66% sand, 5% jsamott A, 7% portland cement 450 and 22% filler.