NZ243913A - Water-resistant building material containing fly ash, cement, gypsum and water-proofing agent - Google Patents

Water-resistant building material containing fly ash, cement, gypsum and water-proofing agent

Info

Publication number
NZ243913A
NZ243913A NZ243913A NZ24391392A NZ243913A NZ 243913 A NZ243913 A NZ 243913A NZ 243913 A NZ243913 A NZ 243913A NZ 24391392 A NZ24391392 A NZ 24391392A NZ 243913 A NZ243913 A NZ 243913A
Authority
NZ
New Zealand
Prior art keywords
water
weight
building material
resistant
resistant building
Prior art date
Application number
NZ243913A
Inventor
Colin David Richards
Graeme Alexander Brown
Dragan Kojic
Original Assignee
Australian Gypsum
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Australian Gypsum filed Critical Australian Gypsum
Publication of NZ243913A publication Critical patent/NZ243913A/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • 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
    • C04B28/14—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 calcium sulfate cements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/04—Cellulosic plastic fibres, e.g. rayon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • 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
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • 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
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
    • 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

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Description

243 9 13 : /3-8"9', : • . . , <• j „ . f pu^ ' !; V 2 7 J U N 1994 ' ' P.O. Jais-rw!. No: ...... ./«??/,... .
No: Date: NEW ZEALAND » < I < 1 \ We, BORAL AUSTRALIAN GYPSUM LIMITED, a company incorporated in the State of Victoria, Commonwealth of Australia of 676 Lorimer Street, Port Melbourne, Victoria, 3207, Australia, do hereby declare the invention, for which we pray that a Patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement:- -l-(Followed by la) - la- 243 9 13 WATER-RESISTANT BUILDING MATERIAL The present invention relates to a water-resistant building material, such as, a panel or sheet.
The building materials currently used in internal wet areas, such as, 25 behind tiles in shower recesses or for external protected areas, for example, eaves lining, are composed of compressed cellulose cement or water-resistant plasterboard.
A requirement accordingly exists for a water-resistant building material which has improved long term water-resistance and maintains an acceptable strength after considerable exposure to moisture. 243 9 13 According to the present invention there is provided a water-resistant building material which comprises: 0.2 to 6% by weight of water-proofing additive; 0.5 to 10% by weight of fly ash; 0 to 5% by weight of Portland cement; and the balance being gypsum and optionally at least one other additive, all of the above percentages by weight being based on the weight of the total composition.
Further according to the present invention there is provided a method for producing a water-resistant building material which comprises: mixing 0.2 to 6% by weight of water-proofing additive, 0.5 to 10% by weight of fly ash, 0 to 5% by weight of Portland cement and the balance being plaster of Paris and optionally at least one other additive with water to form a slurry; pouring the slurry into a mould; allowing the slurry to hydrate and set; and drying the building material at 50 to 150 °C.
Still further according to the present invention there is provided a water-resistant plasterboard construction which comprises: at least one layer of fabric; and a layer of the water-resistant building material described above.
The water-resistant building material is preferably a sheet or panel for internal or external use.
The water-proofing additive may be of any suitable known type, for example, melamine formaldehyde, polyvinyl alcohol, paraffin wax emulsion, silicone emulsion, silicone oil, polyvinyl acetate and bitumen emulsion. Preferably, the concentration of water-proofing additive in the building 243913 material is 0.4 to A% by weight of the total composition.
The concentration of fly ash in the building material is preferably 1 to 6% by weight of the total composition.
Preferably, the concentration of Portland cement in the building material is 0 to 3% by weight of the total composition.
The concentration of gypsum in the building material is preferably 80 to 96% by weight of the total composition.
The other additive which may be present includes fibrous reinforcement, for example, cellulose fibre or chopped fibreglass and light weight filler, for example, waterproof perlite. It will be appreciated that the present invention is not limited to these additives and may include other additives used in the art.
The improved water-resistance is preferably obtained by incorporating low concentrations of fly ash and optionally Portland cement with the plaster of Paris, together with the water-proofing additive. The water-proofing additive acts in conjunction with the low concentrations of ettringite formed and this significantly improves the long term water-resistance compared with that achieved by using the water-proofing additive or the fly ash and Portland cement.
-Thus, in a particularly preferred embodiment, the water-resistant building material comprises: 80 to 96% by weight of gypsum; 0.2 to 6% by weight of water-proofing additive; 0.5 to 10% by weight of fly ash; 0 to 5% by weight of Portland cement; 243 Q 1 7 %jf i 0 0.2 to 3% by weight of fibrous reinforcement; and 0 to 2% by weight of light weight filler, all of the above percentages by weight being based on the weight of total composition.
The water-resistant plasterboard construction preferably comprises one layer of fabric and one layer of paper with the water-resistant building material being sandwiched therebetween. The fabric preferably forms the layer which is exposed to the water.
The fabric may be composed of either naturally occurring fibres or man-made fibres. Preferably, the fabric is composed of man-made fibres based on natural organic polymers such as rayon or of man-made fibres based on synthetic organic polymers such as olefin. Particularly preferred fabrics are 15 viscose rayon, more preferably Lantor (Registered Trade Mark) filter or spunbonded polypropylene, more preferably Evolution (Registered Trade Mark) fabric.
The water-resistant plasterboard construction may be produced by any 20 suitable known process, preferably a continuous process. A particularly preferred continuous process will now be described by way of example only with reference to the accompanying drawing in which: Figure 1 is a side view of a continuous process for the production of a 25 water-resistant plasterboard construction in accordance with the invention.
As shown in the accompanying drawing, the components of the water-resistant building material 2 are metered into a mixer 4 which discharges a slurry 6 onto a layer of paper 8 which is transferred onto a conveyer belt 10. 30 The fabric layer 12 then sandwiches the slurry and after the edges are sealed, the water-resistant building material 2 is allowed to set. During setting, the 2 4 3 9 13 slurry impregnates the fabric and on setting the gypsum crystals formed provide a strong bond with the fabric. The fabric reinforces the surface and contributes significantly to the flexural strength of the plasterboard construction. After the water-resistant building material has set, the 5 plasterboard is cut into desired lengths and dried.
The invention is further described in and illustrated by the following Examples. The Examples are not to be construed as limiting the invention in any way.
The percentages quoted in the Examples are by weight of the total composition.
Example 1 Plaster of Paris 80-96% Water-proofing additive 0.2-6% Fly ash 0.5-10% Portland cement 0-5% Fibrous reinforcement 0.2-3% Waterproof perlite 0-2% The above components were mixed with water in a ratio of 50-90mls of water to lOOgms of powder and other liquid additives used in the art to form a slurry. The slurry was mixed using a suitable mixer such as a propeller type 25 mixer, and was poured into a mould and allowed to hydrate and set. After setting the mould was removed and the cast building slab was dried in a heated air circulating drying kiln.
The water resistant building materials described in the following 30 Examples 2 to 9 were produced in the same manner as Example 1.
Example 2 Plaster of Paris 80-96% Silicone 10% Fly ash 0.5-10% Portland cement 0-5% Waterproof perlite 0-2% Drying temperature 90 °C 10 day water absorption 8.2% Flexural strength 200 Newtons Example 3 Plaster of Paris 80-96% Silicone 4% Fly ash 2% Portland cement 0-5% Fibrous reinforcement 0.2-3% Waterproof perlite 0-2% Drying temperature 70 °C day water absorption 6.9% Flexural Strength 240 Newtons Example 4 Plaster of Paris 80-96% Silicone 1% Fly ash 2% Portland cement 0-5% Fibrous reinforcement 0.2-3% Waterproof perlite 0-2% Drying temperature 50 °C 10 day water absorption 5.0% Flexural Strength 250 Newtons Example 5 Plaster of Paris 80-96% Silicone 1% Fly ash 2% Portland cement 0-5% Fibrous reinforcement 0.2-3% Waterproof perlite 2% Drying temperature 50 "C day water absorption 2.9% Example 6 Plaster of Paris 80-96% Silicone 1% Fly ash 2% Portland Cement 0.5% Fibrous reinforcement 0.2-3% Waterproof perlite 0-2% Drying temperature 80 °C 10 day water absorption 6.0% Example 7 Plaster of Paris 80-96% Paraffin wax emulsion 8% Fly ash 5% Portland cement 0-5% Fibrous reinforcement 0.2-3% Waterproof perlite 0-2% Drying temperature 90 °C day water absorption 6.5% Example 8 Plaster of Paris 80-96% Paraffin wax emulsion 10% Fly ash 3% Portland cement 0-5% Fibrous reinforcement 0.2-3% Waterproof perlite 0-2% Drying temperature 60 °C 10 day water absorption 5.5% Example 9 Plaster of Paris 80-96% Paraffin wax emulsion 6% Fly ash 1% Portland cement 1% Fibrous reinforcement 0.2-3% Waterproof perlite 0-2% Drying temperature 80 °C day water absorption 4.3% 243913

Claims (23)

WHAT WE CLAIM IS:
1. A water-resistant building material which comprises: 0.2 to 6% by weight of water-proofing additive; 5 0.5 to 10% by weight of fly ash; 0 to 5% by weight of Portland cement; and the balance being gypsum and optionally at least one other additive, all of the above percentages by weight being based on the weight of the total composition. 10
2. A water-resistant building material as claimed in Claim 1 wherein the water-proofing additive is selected from melamine formaldehyde, polyvinyl alcohol, paraffin wax emulsion, silicone emulsion, silicone oil, polyvinyl acetate and bitumen emulsion. 15
3. A water-resistant building material as claimed in Claim 1 or Claim 2 wherein the concentration of water-proofing additive is 0.4 to 4% by weight of the total composition. 20
4. A water-resistant building material as claimed in any one of the preceding claims wherein the concentration of fly ash is 1 to 6% by weight of the total composition.
5. A water-resistant building material as claimed in any one of the 25 preceding claims wherein the concentration of Portland cement is 0 to 3% by weight of the total composition.
6. A water-resistant building material as claimed in any one of the preceding claims wherein the concentration of gypsum is 80 to 96%;j?y^ weight f 30 of the total composition. v 1994 01 25 MAR 1994 2 4 3 9 13 -11 -
7. A water-resistant building material as claimed in any one of the preceding claims wherein the at least one other additive is fibrous reinforcement and/or light weight filler. 5
8. A water-resistant building material as claimed in Claim 7 wherein the fibrous reinforcement is cellulose fibre or chopped fibreglass.
9. A water-resistant building material as claimed in Claim 7 or Claim 8 wherein the light weight filler is waterproof perlite. 10
10. A water-resistant building material as claimed in any one of the preceding claims which comprises: 80 to 96% by weight of gypsum; 0.2 to 6% by weight of water-proofing additive; 15 0.5 to 10% by weight of fly ash; 0 to 5% by weight of Portland cement; 0.2 to 3% by weight of fibrous reinforcement; and all of the above percentages by weight being based on the weight of total composition. 20
11. A water-resistant building material as claimed in any one of the preceding claims which is in the form of a sheet or panel for internal or external use. 25
12. A method for producing a water-resistant building material as claimed in any one of the preceding claims which comprises: mixing 0.2 to 6% by weight of water-proofing additive, 0.5 to 10% by weight of fly ash, 0 to 5% by weight of Portland cement and the balance being plaster of Paris and optionally at least one other additive with water to form a 30 slurry; pouring the slurry into a mould; 1 -12 - allowing the slurry to hydrate and set; and drying the building material at 50 to 150 °C. 5
13. A water-resistant plasterboard construction which comprises: at least one layer of fabric; and a layer of the water-resistant building material as claimed in any one of Claims 1 to 11.
14. A water-resistant plasterboard construction as claimed in Claim 10 13 wherein the fabric is composed of either naturally occurring fibres or man- made fibres.
15. A water-resistant plasterboard construction as claimed in Claim 13 or Claim 14 wherein the fabric is composed of man-made fibres based on 15 natural organic polymers or of man-made fibres based on synthetic organic polymers.
16. A water-resistant plasterboard construction as claimed in Claim 15 wherein the man-made fibres based on natural organic polymers are rayon.
17. A water-resistant plasterboard construction as claimed in Claim 15 wherein the man-made fibres based on synthetic organic polymers are olefin
18. A water-resistant plasterboard construction as claimed in any one 25 of Claims 13 to 15 wherein the fabric is viscose rayon or spunbonded polypropylene. 20 -<':i &r :■r o ^ -& MAY 1994 O 13
19. A water-resistant plasterboard construction as claimed in any one of Claims 13 to 18 which comprises one layer of fabric and one layer of paper with the water-resistant building material being sandwiched 5 therebetween.
20. A water-resistant plasterboard construction as claimed in any one of Claims 13 to 19 wherein the fabric forms the layer which is exposed to the water. 10
21. A water-resistant building material as claimed in Claim 1 substantially as herein described.
22. A method for producing a water-resistant 15 building material as claimed in Claim 12 substantially as herein described.
23. A water-resistant plasterboard construction substantially as herein described with reference to the 20 accompanying drawings. 25 BORAL AUSTRALIAN GYPSUM LIMITED By its Attorney DON HOPKINS & ASSOCIATES Per: •t en r^-. .■ V ^0 J *C-Y Y o- f -5 MAY 1994
NZ243913A 1991-08-13 1992-08-11 Water-resistant building material containing fly ash, cement, gypsum and water-proofing agent NZ243913A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPK773491 1991-08-13
AUPK960991 1991-11-22

Publications (1)

Publication Number Publication Date
NZ243913A true NZ243913A (en) 1994-06-27

Family

ID=25644093

Family Applications (1)

Application Number Title Priority Date Filing Date
NZ243913A NZ243913A (en) 1991-08-13 1992-08-11 Water-resistant building material containing fly ash, cement, gypsum and water-proofing agent

Country Status (3)

Country Link
EP (1) EP0599872A4 (en)
NZ (1) NZ243913A (en)
WO (1) WO1993004007A1 (en)

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US5439518A (en) * 1993-01-06 1995-08-08 Georgia-Pacific Corporation Flyash-based compositions
FR2705608A1 (en) * 1993-05-26 1994-12-02 Carlucci Pierre Method of manufacturing lightened insulating panels for buildings
CN1042828C (en) * 1993-10-30 1999-04-07 夏咏荷 Water-proof plaster products
GB9626320D0 (en) * 1996-12-19 1997-02-05 Ecc Int Ltd Cementitious compositions
US5817262A (en) * 1996-12-20 1998-10-06 United States Gypsum Company Process of producing gypsum wood fiber product having improved water resistance
US6010596A (en) * 1996-12-20 2000-01-04 United States Gypsum Company Gypsum wood fiber product having improved water resistance
AU748229B2 (en) * 1997-12-03 2002-05-30 Ssangyong Cement (Singapore) Limited Waterproofing additive for cement and concrete comprising modified pozzolanic materials
GB2336360B (en) * 1998-04-17 2002-04-24 Bpb Plc Gypsum products
US6315825B1 (en) 1999-12-06 2001-11-13 Great Barrier Technologies, Inc. Composition and process for improving the resistance to water penetration of cementitious products and cementitious products made therewith
CN1234799C (en) * 2004-05-28 2006-01-04 胡斌 Thermal insulative energy-saving waterproof cream and preparing method thereof
WO2011087781A2 (en) * 2009-12-22 2011-07-21 Georgia-Pacific Gypsum Llc Method of manufacturing water-resistant gypsum articles and articles formed thereby
US8038790B1 (en) 2010-12-23 2011-10-18 United States Gypsum Company High performance non-combustible gypsum-cement compositions with enhanced water durability and thermal stability for reinforced cementitious lightweight structural cement panels
CA2849079C (en) 2011-09-21 2019-06-11 Donaldson Company, Inc. Fine fibers made from polymer crosslinked with resinous aldehyde composition
CN102757196B (en) * 2012-07-25 2013-09-11 天津市南开区房地产管理局 Waterproof cement additive and cement containing same
EP2964817A1 (en) 2013-03-09 2016-01-13 Donaldson Company, Inc. Fine fibers made from reactive additives
CN105174892B (en) * 2015-09-14 2018-01-19 河南聚能新型建材有限公司 A kind of light gypsum compound prescription and the construction method using its cast-in-place gypsum wall

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US2526538A (en) * 1946-11-16 1950-10-17 United States Gypsum Co Water-resistant gypsum products and method of making
US3869415A (en) * 1968-04-04 1975-03-04 Temec Limited Resinous polymer containing waterproofing plaster compositions
GB1302592A (en) * 1970-02-04 1973-01-10
DK1978A (en) * 1978-01-03 1979-07-04 I S Hansen PROCEDURE FOR MANUFACTURE OF A DRAWER
JPS57118055A (en) * 1981-01-16 1982-07-22 Ube Industries Gypsum composition
DE3111309A1 (en) * 1981-03-23 1982-10-14 Gebr. Knauf Westdeutsche Gipswerke, 8715 Iphofen Building plaster
IN168901B (en) * 1986-12-09 1991-07-06 Raffaele Cioffi

Also Published As

Publication number Publication date
EP0599872A4 (en) 1994-07-13
EP0599872A1 (en) 1994-06-08
WO1993004007A1 (en) 1993-03-04

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