PT108904B - DENSE-FREE CORK-BASED MORTAR FORMULATIONS - Google Patents

Abstract

THIS INVENTION CONCERNS FORMULATIONS OF CORK-BASED MORTGAGE FREE OF DENSE AGGREGATES, AS WELL AS MORTARS UNDERSTANDING THE FORMULATIONS AND USE OF MORTARS. THE MORTAR FORMULATION OF THE INVENTION CONSISTS OF: A) 59 TO 66% OF LEADERS; B) 8 to 16% of cork material; (C) 9 to 21% of the group's selected material consisting of exfoliated vERMICULITE, EXPANDED PERLITE, EXPANDED GLASS AND COMBINATION; AND D) 1 TO 22% ADDITIVES. THE INVENTION FINDS APPLICATION IN THE CONSTRUCTION INDUSTRY, IN PARTICULAR IN THE MAINTENANCE AND CONSTRUCTION OF BUILDINGS, BECAUSE ITS COMPOSITION IS FREE OF DENSE AGGREGATES, FOR EXAMPLE SAND.

Description

DENSE-FREE CORK-BASED MORTAR FORMULATIONS

FIELD OF INVENTION

The present invention relates to dense aggregate-free cork-based mortar formulations. The invention further relates to mortars comprising said formulations and applications of such mortars. The invention finds application in the construction industry, particularly in the maintenance and construction of buildings, and its composition is free of dense aggregates, for example silica and calcium carbonate.

BACKGROUND OF THE INVENTION

Traditional mortars have a high density (between 1400 and 1800 kg / m ³ ) and have a negative contribution to thermal and acoustic insulation.

PT 103641 discloses a mortar consisting of air lime, cork, pozzolans, sand and fibers and uses cork boards to achieve the stated thermal insulation levels.

EN 105937 relates to lightweight mortar consisting of limestone or silicon aggregate, Portland cement, cork granules, calcium or magnesium hydroxide and other components. However, their formulation is present and dense aggregates are required.

FR 2681856 discloses cellular mortars for acoustic insulation based on cork granules, synthetic resin and a mineral material, for example bentonite.

In Development of improved thermal behavior mortar, Márcio Leal, Master's degree thesis, Polytechnic Institute of Setúbal, 2012, are disclosed thermal behavior mortar with a cement-based binder and cork granules or with expanded polystyrene, having in its constitution about 20% of dense aggregate.

PT 107173 discloses a mortar consisting of hydraulic lime, cork, silicon dense aggregates and superplasticizer. This formulation does not dispense with dense aggregates.

The incorporation of dense aggregates in mortars has the function of giving dimensional stability to the mortar, with repercussions mainly in terms of shrinkage reduction and cracking. These dense aggregates give their mortars inferior performances in terms of their thermal efficiency.

There is a need in the art for a lightweight, low thermal coefficient mortar with good acoustic absorption in the bass range, allowing the use of dense aggregates in their formulation and providing greater application versatility.

SUMMARY OF THE INVENTION

The present invention relates to cork-based mortar formulations comprising:

a) 59 to 66% of binders;

b) 8 to 16% of cork material;

(c) 9 to 21% of material selected from the group consisting of exfoliated vermiculite, expanded perlite, expanded glass and combinations thereof; and

d) 1 to 22% of additives.

Preferably, the binders are selected from the group consisting of hydrated aerial lime, natural hydraulic lime, hydraulic lime, Portland cement, natural cement and combinations thereof.

In another embodiment cork is cork granulate or or a combination of expanded cork granulate.

of the invention, the expanded cork

In yet another embodiment, the additives are selected from the group consisting of the thickening additive, adhesive and cohesion additive, hydraulic additive, moisture retaining additive, plasticizing additive, hydrophobic additive, biocidal additive and setting accelerator additive and combinations thereof.

In one embodiment, the mortar formulations consist of:

a) 60 to 63% of binders;

b) 8 to 10% of cork material;

(c) 9 to 13% of material selected from the group consisting of exfoliated vermiculite, expanded perlite, expanded glass and combinations thereof; and

d) 15 to 22% of additives.

In a preferred embodiment, the mortar formulation consists of:

a) 63.0% of natural hydraulic lime;

b) 9.7% of expanded cork granules;

c) 5.3% exfoliated vermiculite and 5.1% expanded perlite; and

(d) 0,6% thickening additive, 11,6% hydraulic additive, 2,9% moisture retaining additive, 0,8% plasticizing additive and 1,0% hydrophobic additive.

In another preferred embodiment, the mortar formulation consists of:

(a) 4,3% hydrated aerial lime, 55,2% natural hydraulic lime and 6,1% natural cement;

b) 8.4% of expanded cork granules;

c) 6.2% exfoliated vermiculite, and 3.3% perlite; and

d) 0.5% thickening additive, 10.8% hydraulic additive, 2.7% moisture retaining additive, 0.7% plasticizer additive, 0.9% hydrophobic additive and 0.9% additive biocide.

In yet another preferred embodiment, the mortar formulation consists of:

(a) 62,4% hydrated aerial lime;

b) 8.1% of cork granules;

c) 5.2% exfoliated vermiculite and 7.4% expanded perlite; and

d) 0.6% thickening additive, 11.6% hydraulic additive, 2.9% moisture retaining additive, 0.8% plasticizing additive, and 1.0% hydrophobic additive.

In a particularly preferred embodiment, the mortar formulation consists of:

a) 62.0% Portland cement;

b) 6.4% of cork granules and 9.0% of expanded cork granules;

c) 1.8% exfoliated vermiculite and 19.0% expanded glass; and

c) 0.8% plasticizer additive and 1.0% hydrophobic additive.

In a most preferred embodiment, the mortar formulation consists of:

a) 46.3% hydraulic lime and 13.3% natural cement;

(b) 1,3% cork granules and 7,9% expanded cork granules;

c) 4.7% exfoliated vermiculite and 4.5% expanded perlite; and

d) 0.6% thickening additive, 2.3% adhesive and cohesion additive, 11.0% hydraulic additive, 2.8% moisture retaining additive, 0.7% plasticizing additive, 0.9 % hydrophobic additive and 3.7% prey accelerator additive

The present invention also relates to a mortar comprising the formulation defined above.

The present invention further relates to the use of the mortar of the present invention for application by mechanical projection, injection, manual, or in the production of slabs.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to dense aggregate-free cork-based mortar formulations for use in the construction industry, particularly in the maintenance and construction of buildings.

Unless otherwise indicated, the percentages mentioned in the present description and claims refer to percentages by mass.

In the context of the present disclosure, the term comprising is to be understood to include, among others. As such, that term should not be construed as consisting solely of.

Note that any X-value presented in the course of the present disclosure should be interpreted as an approximate value of the actual X-value, as such approximation to the actual value would be reasonably expected by one skilled in the art due to experimental and / or measurement conditions that introduce deviations from the actual value.

Unless otherwise indicated, the ranges of values set forth herein are intended to provide a simplified and technically acceptable way to indicate each individual value within its range. By way of example, the expression 1 to 2 or between 1 and 2 means any value within this range, for example 1.0; 1.1; 1,2; 1.3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9; 2.0. All values mentioned in this description are to be construed as approximate values in the sense previously adopted. For example a reference to 2.3 means about 2.3.

The term binder or binders refers to one or more products that agglomerate aggregates creating cohesive and mechanically resistant products. Examples are hydrated aerial lime, natural hydraulic lime, hydraulic lime, Portland cement and natural cement. They may have hydraulic properties when they react (harden) with water. If they do not react with water, they are called air binders, as is the case with air docks. Chemically there are differences between the ligands:

Air lime according to NP-EN 459-1 is mainly composed of calcium oxide or hydroxide and slowly hardens in air by reaction with atmospheric carbon dioxide. Since it has no hydraulic properties, this lime does not carbonate in the presence of water. It comes in the form of quicklime or hydrated lime. The preferred air lime in the present invention is hydrated calcified powder;

Natural hydraulic lime is mostly made up of calcium silicates and aluminates and calcium hydroxide. According to NP-EN 459-1, it is a lime produced by burning siltaceous limestone with extinction dust reduction, with or without grinding. Natural hydraulic lime has the property of gaining prey (i.e. carbonate in the presence of water) and hardening in water. Atmospheric carbon dioxide also contributes to its hardening by reaction with calcium hydroxide. The preferred natural hydraulic lime is NHL 3.5 R, powder;

Hydraulic lime can be obtained by mixing between an air lime and a cement. According to NP-EN 459-1, it is a lime mainly composed of calcium hydroxide, calcium silicates and calcium aluminates, produced with a mixture of suitable materials. Hydraulic lime has the property of setting and hardening in water. 0 atmospheric carbon dioxide also

contributes for its reaction hardening with O hydroxide in calcium. The preferred hydraulic lime it's HL 5 R, in powder; and cement, is mainly made up of silicate and aluminate in calcium. It is obtained from mixture in

limestone, clay or clay shale, marl or marshy limestone and other materials rich in silica, alumina or iron. As defined in EN 197-1, cement is a hydraulic binder, ie a finely ground inorganic material which when mixed with water forms a paste which hardens by hydration reactions and processes and which, after hardening, retains its strength. Resistant capacity and stability even under water. The preferred cement is Portlant CEM I 32.5 R cement and natural cement according to the same standard.

The term dense aggregates in the context of the present description refers to aggregates with normal or heavy density, ie with a density greater than 2000 or greater than 3000 kg / m ³ , respectively, when determined in accordance with EN 1097-6.

The term light aggregates, in the context of the present description, refers, in accordance with EN 13055-1, to aggregates having an oven density of less than or equal to 2000 kg / m ³ when determined in accordance with EN 13055-1. EN 1097-6, or with a bar after oven drying, less than or equal to 1200 kg / m ³ when determined in accordance with EN 1097-3. According to the same standard, barity is the ratio between the mass of the uncompressed dry aggregate that fills a particular container and the capacity of that container. Ultralight aggregates are aggregates with an oven-dryness of less than or equal to 300 kg / m ³ when determined in accordance with EN 1097-3.

In the context of the present invention, the term light aggregates refers to cork material as well as exfoliated vermiculite, expanded perlite, expanded glass or combinations thereof.

The term cork material refers to cork granules, expanded cork granules or combinations thereof.

The term granulated cork refers to the product obtained by crushing the suber layer of the cork oak, as well as the product obtained by recycling and subsequent crushing of cork products (natural or agglomerated) such as corks. The particle size used varies between 0,005 and 4 mm, the thermal conductivity is 0,050 W / m. ° C and has a density between 60 and 130 Kg / m ³ .

The term expanded granulated cork refers to black cork fragments obtained after cooking in autoclaves (using water vapor at a temperature of about 300 to 400 ° C for a time period of 15 to 20 minutes) of falca shredded (ie virgin, secondary or pruned cork subjected to shredding), cork granules, bits, scrap and waste from other industrial cork processing operations. The particle size used in the agglomerated expanded cork used in the present invention varies between 0.005 and 2 mm, the thermal conductivity is 0.040 W / m. ° C and has a density between 60 and 70 kg / m ^3.

Vermiculite consists mainly of hydrous aluminum and magnesium silicates and is classified as a clay (hydrated phyllosilicate) and does not fit into so-called silicate aggregates. The so-called silicate aggregates are mainly formed by SiO ₂ (tectosilicates) and are in the category of dense aggregates, absent from the mortar formulations of the present invention. Vermiculite is an ultralight aggregate when expanded by temperature. It is also commonly termed as exfoliated vermiculitis.

Expanded perlite may be included in the composition of the mortar formulations of the present invention as an aggregate and may be termed as hydrated volcanic glass. It is also an ultralight aggregate.

Expanded glass is a glass with low density, also referred to as glass microspheres.

It is an object of the invention to obtain a mortar having an improved thermal behavior with a thermal conductivity coefficient of less than

0.10

W / m ² C (class TI according to EN NP 998-1) or between

0.15 and

0.10 W / m. ² C

T2 according to the same standard) as well as good sound absorption in the bass range.

The mortar formulations of the present invention differ from known prior art mortars in that they do not comprise dense aggregates (silicate and limestone aggregates) and wood or mineral vegetable fibers used in prior art mortars.

Surprisingly, the mortar formulations of the invention exhibit unexpected physical-mechanical behavior in the absence of dense aggregates, which give traditional mortars the necessary body for their application and performance.

The mortar formulations of the invention have additional features such as their low barity and high durability.

Due to their physical-mechanical behavior, the mortars of the present invention have a great versatility in their application, allowing them to be made manually, by injection, or by projection on different support materials and surface type, surface and floor. These 11 mortar formulations provide varying mortar thicknesses of up to 75 mm per application layer, without prior support regularization and fresh formulation.

The mechanical strength of the mortars of the present invention is suitable for rehabilitation or new construction, with good adhesion to traditional (stone masonry) or contemporary (brick masonry) supports and low shrinkage. The presence of additives improves the mechanical characteristics of adhesion, cohesion and compatibility.

The mortar formulations of the invention provide both thermal and acoustic enhancement of comfort within the spaces where it is used.

Cork-based mortar formulations are characterized by:

a) 59 to 66% of binders;

b) 8 to 16% of cork material;

(c) 9 to 21% of material selected from the group consisting of exfoliated vermiculite, expanded perlite, expanded glass and combinations thereof; and

d) 1 to 22% of additives.

Binders are selected from the group comprising hydrated aerial lime, natural hydraulic lime, hydraulic lime, Portland cement and natural cement and their combinations. The selection of the binder and its combinations will depend on the desired characteristics, and the most versatile binder is natural hydraulic lime. For functions with no mechanical input (eg filler drops) the binder to be selected will be hydrated air lime and for floors will be Portland cement, for walls the most suitable binder will be natural hydraulic lime or hydraulic lime. The mechanical characteristics of the substrate (type of wall and type of mortar present) should be taken into account and agreement on mechanical properties. These characteristics shall and may be adjusted in the ratio of binder to aggregate.

In one embodiment, the cork material is cork granulate. In another embodiment, the cork material is granulated expanded cork. In yet another embodiment, the cork material is a combination of cork granules and expanded cork granules.

All of the above lightweight aggregates may enter the mortar formulations of the present invention to achieve the desired compactness (minimizing void volume, enhancing binder binding properties) of cork and may be alternatives to each other. The matrix of the mortar formulations of the invention is essentially conferred by cork. It should be noted that all built-in aggregates contribute with thermal insulation characteristics. This is not the case with dense aggregates. These even have an antagonistic thermal contribution.

The density of these materials is quite low and can be considered as ultra-light aggregates as they have a density of less than 300 kg / m ³ .

In prior art formulations, the matrix is imparted by the dense (silicon density greater than 2000 kg / m ³ ) aggregate, where cork, when present, functions as an additive.

The additives that are used in the preparation of the mortar formulations of the present invention may be quite varied and have very specific functions.

The additives are selected from the group comprising thickener additive, adhesive and cohesion additive, hydraulic additive, moisture retaining additive, plasticizer additive, hydrophobic additive, biocidal additive and prey accelerator additive and combinations thereof.

In one embodiment, the additives are present in the following proportions:

• Thickener additive: up to 1%.

• Adhesive and cohesive additive: up to 3%.

• Hydraulic additive: up to 12%.

• Moisture-retaining additive: up to 3%.

• Air introducer and plasticizer additive: up to 1%.

• Hydrophobic additive: up to 1%.

• Biocidal additive: up to 1%.

• Setting accelerator additive: up to 4%.

The adhesive and cohesive additive is selected from the group comprising acrylic, polyvinyl resins or mixtures thereof.

thickening additive is a cellulose derivative selected from the group comprising cellulose ether, methylethylcellulose, modified starch and vegetable fiber and combinations thereof.

Hydraulic additive is a natural or artificial pozzolan selected from the group comprising metacaulin, fly ash and natural volcanic ash and combinations thereof.

As a moisture retaining additive a clay is used, for example using a phyllosilicate (magnesium silicate).

Preferably the plasticizer additive is a lauryl sulfate.

Preferably the hydrophobic additive is a siloxane or a layer thereof.

Preferably, the biocidal additive is titanium dioxide.

prey accelerator additive is selected from the group comprising calcined amorphous alumina.

In one embodiment, the mortar formulations of the invention consist of:

a) 60 to 63% of binders;

b) 8 to 10% of cork material;

(c) 9 to 13% of material selected from the group consisting of exfoliated vermiculite, expanded perlite, expanded glass and combinations thereof; and

d) 15 to 22% of additives.

The present invention also relates to mortars comprising the formulations described above.

Preferably, those applied by mechanical projection, may be used in the production of mortars of the invention are by injection, manually and plates.

The following are examples of mortar formulations of the present invention, fresh mortar preparation processes and their applications.

Example 1

Type Component Quantity (kg) Binder Natural hydraulic lime 0.6293 Aggregates Expanded Cork Granules 0.0972 Exfoliated Vermiculitis 0.0534 Expanded perlite 0.0514 Additions Thickener 0.0059 Hydraulic 0.1662 Moisture retainer 0.0290 Air introducer, plasticizer 0.0078 Hydrophobic 0.0098 Total 1, 0000

The following Table 1 presents the physical and mechanical parameters of the present exemplary formulation:

Table 1

Feature Units Test Assay Values Class Class EN 1015-1 - T Appearance Gray powder Dry density kg / m ³ EN 1015-1 335 Maximum diameter of the aggregate mm EN 993-1 1.0 Fresh produce Density kg / m ³ EN 1015-10 674 Kneading water O 0 EN 1015-3 96 Consumption kg / m ² / cm 3, 8 Consistency mm EN 1015-3 - Final results (28 days) Thermal conductivity W / m. ° C EN 12667 0.077 YOU Compressive strength N / mm ² EN 1015-11 0.67 CSI Bending tensile strength MPa EN 1015-11 0.37 Modulus of elasticity MPa BS 1881-18 390 Water absorption EN 1015-18 0.31 W1

The mortar obtained has a density of 674 kg / m ³ and has a thermal conductivity of 0,077 W / m. ° C.

The formulated mortar has been found to be a lightweight mortar particularly suitable for mechanical projection application on exterior and interior walls.

The addition of water should be 0.96 1 / kg, and this mortar should be applied by mechanical projection after premixing. The recommended maximum thickness per layer is 75 mm.

Example 2:

Type Component Quantity (kg) Binder Hydrated air lime 0.0425 Natural hydraulic lime 0.5511 Natural cement 0.0611 Aggregate s Expanded Cork Granules 0.0844 Exfoliated Vermiculitis 0.0619 Expanded perlite 0.0335 Additions Thickener 0.0054 Hydraulic 0.1079 Moisture retainer 0.0270 Air introducer, plasticizer 0.0072 Hydrophobic 0.0090 Biocide 0.0090 Total 1.0000

The following Table 2 presents the physical-mechanical parameters of the present exemplary formulation:

Table 2

Feature Units Test Assay Values Class Class EN 1015-1 - T Appearance Gray powder Dry density kg / m ³ EN 1015-1 370 Maximum diameter of the aggregate mm EN 993-1 1.0 Fresh produce Density kg / m ³ EN 1015-10 692 Kneading water O 0 EN 1015-3 85 Consumption kg / m ² / cm 4.0 Consistency mm EN 1015-3 - Final results (28 days) Thermal conductivity W / m. ° C EN 12667 0.088 YOU Compressive strength N / mm ² EN 1015-11 1.16 CSI Bending tensile strength MPa EN 1015-11 0.61 Modulus of elasticity MPa BS 1881-18 519 Water absorption EN 1015-18 0.22 W1

The mortar obtained has a density of 692 kg / m ³ and has a thermal conductivity of 0,088 W / m. ° C.

The formulated mortar has been found to be a light mortar particularly suited for manual application in exterior and interior walls.

The addition of water should be 0.85 1 / kg and this mortar should be applied manually after premixing.

Example 3

Type Component Quantity (kg) Binder Hydrated air lime 0.6253 Aggregates Cork granules 0, 0 8 0 9 Exfoliated Vermiculitis 0, 0 516 Expanded perlite 0.0743 Additions Thickener 0.0059 Hydraulic 0 1! 5 5 Moisture retainer 0.0289 Air introducer, plasticizer 0.0078 Hydrophobic 0.0098 Total 1.0000

The following Table 3 presents the physical-mechanical parameters of the present exemplary formulation:

Table 3

Feature Units Test Assay Values Class Class EN 1015-1 - T Appearance White powder Dry density kg / m ³ EN 1015-1 273 Maximum diameter of the aggregate mm EN 993-1 1.0 Fresh produce Density kg / m ³ EN 1015-10 789 Kneading water O 0 EN 1015-3 144 Consumption kg / m ² / cm 3, 9 Consistency mm EN 1015-3 - Final results (28 days) Thermal conductivity W / m. ° C EN 12667 0.070 YOU Compressive strength N / mm ² EN 1015-11 0.23 - Bending tensile strength MPa EN 1015-11 0.13 Modulus of elasticity MPa BS 1881-18 164 Water absorption EN 1015-18 1.08 wo

The mortar obtained has a density of 789 kg / m ³ and a thermal conductivity of 0,070 W / m. ° C.

The formulated mortar has been found to be a lightweight mortar particularly suited for injection application, ie it is suitable for filling air-box without thermal insulation such as double perforated brick masonry.

The addition of water should be 1.44 l / kg, and this mortar should be applied by injection after premixing.

Example 4

Type Component Quantity (kg) Binder Portland cement 0.6215 Aggregates Cork granules 0.0635 Expanded Cork Granules 0.0895 Exfoliated Vermiculitis 0.0182 Expanded glass 0.1896 Additions Air introducer, plasticizer 0.0079 Hydrophobic 0.0098 Total 1.0000

The following Table 4 presents the physical-mechanical parameters of the present exemplary formulation:

Table 4

Feature Units Test Assay Values Class Class EN 1015-1 - T Appearance Gray powder Dry density kg / m ³ EN 1015-1 423 Maximum diameter of the aggregate mm EN 993-1 4.0 Fresh produce Density kg / m ³ EN 1015-10 762 Kneading water O 0 EN 1015-3 51 Consumption kg / m ² / cm 5, 1 Consistency mm EN 1015-3 - Final results (28 days) Thermal conductivity W / m. ° C EN 12667 0, 110 T2 Compressive strength N / mm ² EN 1015-11 2.23 - Bending tensile strength MPa EN 1015-11 1.32 Modulus of elasticity MPa BS 1881-18 1386 Water absorption EN 1015-18 0.04 W2

The mortar obtained has a density of 762 kg / m ³ and has a thermal conductivity of 0,11 W / m. ° C.

It has been found that the formulated mortar is a light mortar particularly suitable for manual application to floors.

The addition of water should be 0.51 l / kg and this mortar should be applied manually after premixing.

Example 5

Type Component Quantity (kg) Binder Hydraulic lime 0.4634 Natural cement 0.1329 Aggregates Cork granules 0.0129 Expanded Cork Granules 0.0791 Exfoliated Vermiculitis 0.0471 Expanded perlite 0.0453 Additions Thickener 0.0055 Cohesion and accession 0.0230 Hydraulic 0.1101 Moisture retainer 0.0275 Air introducer, plasticizer 0.0073 Hydrophobic 0.0092 Prey Throttle 0.0367 Total 1.0000

The following Table 5 presents the physical-mechanical parameters of the present exemplary formulation:

Table 5

Feature Units Test Assay Values Class Class EN 1015-1 - T Appearance Gray powder Dry density kg / m ³ EN 1015-1 350 Maximum diameter of the aggregate mm EN 993-1 1.0 Fresh produce Density kg / m ³ EN 1015-10 685 Kneading water O 0 EN 1015-3 0.99 Consumption kg / m ² / cm 3, 6 Consistency mm EN 1015-3 - Final results (28 days) Thermal conductivity W / m. ° C EN 12667 0.94 YOU Compressive strength N / mm ² EN 1015-11 0.69 CSI Bending tensile strength MPa EN 1015-11 0.39 Modulus of elasticity MPa BS 1881-18 420 Water absorption EN 1015-18 0.30 W1

The mortar obtained has a density of 685 kg / m ³ and has a thermal conductivity of 0,094 W / m. ° C.

The formulated mortar has been found to be a lightweight mortar particularly suited for the production of insulating boards for exterior wall application.

The addition of water should be 0.99 l / kg and this mortar should be poured into molds after premixing.

Example 6

The production of the different mortar formulations corresponding to examples 1 to 4 is carried out in a mixer where the various components enter sequentially, where the lower specific weight components are the first to be incorporated. Mixing is performed until product homogeneity occurs.

The mixtures obtained incorporate all components and must be suitably bagged so that no binder contact with moisture occurs until the time of mixing on site.

The addition of water, already in the works, should occur 5-10 minutes before the application of the product, proceeding to its mixing mechanically and the low rotation, being that each of the formulations will have to receive specific amounts of water to

catch up The workability desired and catch up at features physical-mechanical planned.

Example 7

Factory sheet molding is possible to produce prefabricated parts using the cork mortar formulations of the present invention. For this purpose the formulation of example 5 should be used, respecting the production phase, followed by the incorporation of water and its homogenization. The obtained paste should be poured into molds of the desired size and thickness and allowed to cure and then stored. The usual size for this kind of product is 1.2 by 0.6 m and with varying thicknesses between 40 and 80 mm.

Larger plates can be produced and, once dried, can be cut to desired size.

Example 8

Prior to the application of the mortar of the present invention, the substrate must be cleaned and prepared by brushing or chopping so that disaggregated materials and dust are eliminated. Salts, fats and other contaminants should also be eliminated.

After this operation, the substrate should be well moistened the day before application with clean water. On very absorbent substrates, wetting should be repeated before application.

a) Projection mortar - use of spray gun

If the application is made using a spray gun-type device, it is filled with the projection mortar (example 1). Then the gun is directed to the holder to be coated and its trigger is triggered, applying the mortar to the holder. A slurry spray (mortar applied to the substrate) should be applied beforehand to improve adherence of the next layer. Immediately afterwards, the plaster is applied. If thicknesses greater than 75 mm are desired, the previous layer should be allowed to dry.

When the mortar begins to harden, finish using a trowel.

b) Projection mortar - use of continuous projection machine

If spraying mortar (example 1) is applied using a continuous spraying machine, after preparation, the applicator will pour the mortar into the hopper of the machine. It then directs the tip to the support to be coated and triggers the trigger, thus applying the mortar to the support. As described above, a slurry spray must be applied in advance, followed by plastering. If thicknesses greater than 75 mm are desired, the previous layer must be allowed to harden.

When the mortar begins to harden, finish using a trowel.

c) Mortar of manual application

When the mortar is to be applied manually (example 2) it must be applied with the aid of a trowel, layered to the desired thickness. When the mortar begins to harden, finish using a trowel.

d) Injection mortar

For the application of the mortar (example 3) to be made by injection it is necessary to make small holes in the walls to inject the mortar in the air cavities, cavities or hollow, to fill the existing voids. Preliminary work should be carried out, in particular the elimination of all cracks, cracks and holes through which the injection mortar may flow undesirable (leakage).

Due to its fluidity, it is ideal for the rehabilitation of existing buildings, particularly for filling air boxes.

This type of mortar is also used as a complement to other traditional insulations, namely rock wool or polystyrene, as it acts in the air box involving the existing insulation and filling the voids.

e) Mortar for floor application

When mortar is to be applied to floors (example 4), it must be poured in place and smoothed manually or with a squeegee until it reaches the desired thickness. Then, with the help of a ruler, the surface is smoothed. When the mortar begins to harden, finish using a trowel.

Example 9

After molding slabs in the factory to produce prefabricated pieces using the mortar of example 5, the application of said mortar plates on site must be mechanically nailed, preceded by the manual application of the formulation of example 2 with a spoon. bricklayer to a minimum thickness of 5 mm and a maximum thickness of 10 mm. The goal is to achieve a smooth and smooth surface to support the plates. The plate should be thin layered with the formulation of Example 2, less than 10 mm thick, armed with a stress-relieving mesh (fiberglass mesh or non-woven fabric) in the middle of this last finishing layer.

Lisbon, October 22, 2015

Claims (14)

1. Cork-based mortar formulation consisting of: a) 59 to 66% of binders; b) 8 to 16% of cork material; (c) 9 to 21% of material selected from the group consisting of exfoliated vermiculite, expanded perlite, expanded glass and combinations thereof; and d) 1 to 22% of additives. Mortar formulation according to claim 1, characterized in that the binders are selected from the group consisting of hydrated air lime, natural water lime, water lime, Portland cement, natural cement, and combinations thereof. Mortar formulation according to Claim 1, characterized in that the cork material is cork granulated. Mortar formulation according to claim 1, characterized in that the cork material is expanded cork granulate. Mortar formulation according to claim 1, characterized in that the cork material is a combination of cork granules and expanded cork granules. Mortar formulation according to claim 1, characterized in that the additives are selected from the group consisting of thickener, adhesive and cohesion, hydraulic, moisture retainer, plasticizer, hydrophobic, biocide and setting accelerator and combinations thereof. Mortar formulation according to any one of Claims 1 to 6, characterized in that it comprises: a) 60 to 63% of binders; b) 8 to 10% of cork material; (c) 9 to 13% of material selected from the group consisting of exfoliated vermiculite, expanded perlite, expanded glass and combinations thereof; and d) 15 to 22% of additives. Mortar formulation according to claim 1, characterized in that it consists of: a) 63.0% of natural hydraulic lime; b) 9.7% of expanded cork granules; c) 5.3% exfoliated vermiculite and 5.1% expanded perlite; and (d) 0,6% thickening additive, 11,6% hydraulic additive, 2,9% moisture retaining additive, 0,8% plasticizing additive and 1,0% hydrophobic additive. Mortar formulation according to claim 1, characterized in that it consists of: (a) 4,3% hydrated aerial lime, 55,2% natural hydraulic lime and 6,1% natural cement; b) 8.4% of expanded cork granules; c) 6.2% exfoliated vermiculite, and 3.3% perlite; and d) 0.5% thickening additive, 10.8% hydraulic additive, 2.7% moisture retaining additive, 0.7% plasticizer additive, 0.9% hydrophobic additive and 0.9% additive biocide. 10 Mortar formulation according to claim 1, characterized in that it consists of: (a) 62,4% hydrated aerial lime; b) 8.1% of cork granules; c) 5.2% exfoliated vermiculite and 7.4% expanded perlite; and d) 0.6% thickening additive, 11.6% hydraulic additive, 2.9% moisture retaining additive, 0.8% plasticizing additive, and 1.0% hydrophobic additive. 11 Mortar formulation according to claim 1, characterized in that it consists of: a) 62.0% Portland cement; b) 6.4% of cork granules and 9.0% of expanded cork granules; c) 1.8% exfoliated vermiculite and 19.0% expanded glass; and c) 0.8% plasticizer additive and 1.0% hydrophobic additive. 12 Mortar formulation according to claim 1, characterized in that it consists of: a) 46.3% hydraulic lime and 13.3% natural cement; (b) 1,3% cork granules and 7,9% expanded cork granules; c) 4.7% exfoliated vermiculite and 4.5% expanded perlite; and (d) 0,6% thickening additive, 2,3% adhesive and cohesive additive, 11,0% hydraulic additive, 2,8% moisture retaining additive, 0,7% plasticizing additive, 0,9 % hydrophobic additive and 3.7% prey accelerator additive Mortar comprising the formulation of any one of claims 1 to 12. Use of mortar according to claim 13, characterized in that it is applied in the production of slabs.