RU2223931C1 - Polystyrene/concrete products' manufacture process - Google Patents

Abstract

FIELD: manufacture of building materials. SUBSTANCE: polystyrene/concrete products with heat-insulation and construction properties are manufactured from composition containing, wt %: Portland cement 68-70, granulated foamed polystyrene 3-6, reinforcing material 5-12 (above 100%), air-entrainment agent (saponified wood resin) 0.02-0.1, plasticizing agent 0.1-0.2, and water (balancing amount). Specified amount of granulated foamed polystyrene is fed into concrete mixer, moistened with a part of tempering water at stirring, and then cement, the rest of tempering water, air- entrainment and plasticizing agents are added. The mix is stirred and molded into products, which is subjected to heat treatment. Saponified wood resin is preliminarily diluted with water at ratio between 1:5 and 1:19 to 8-12% concentration, after which held up to 48 h at 15-35 C. Granulated foamed polystyrene with loose density 25-30 kg/cu.m, fraction 3-5 mm, is moistened with 1/3 tempering water and stirred during 0.5-1.5 min. After addition of Portland cement, the total is stirred for 30-60 sec and then are added remaining 2/3 tempering water, preliminarily diluted saponified wood resin and lignosulfonate or superplasticizer S3 (plasticizers). Resulting mix is stirred for at least 2 min and thoroughly warmed from cement hydration heat to temperature 35-75 C until coherent porized homogenous structure is obtained. When molding, polystyrene/concrete mix is delivered with the aid of screw pump into concrete form with, installed therein, cellular framework made from reinforcing material: threads or sticks with diameter (0.5-3)d, cells (50- 100)x(50-100)d, laid in 2-4 layers, and binding transversal sticks with diameter (1.0-4)d and step (100-200)x(100- 200)d, where d is average diameter of polystyrene granules. Protective layer between concrete reinforcement and outside surface is at least 25 mm. Mix filling concrete form is smoothed and held at 15-35 C for at least 12 h. Thus obtained polystyrene/concrete product, after stripping of formwork, is sprayed during 30 days with water once every three days starting from 8th day after laying mix into form. EFFECT: decreased bulk weight and heat conductivity of products, and reduced consumption of starting components. 1 tbl

Description

The invention relates to the production of building materials, in particular polystyrene concrete products with thermal insulation and structural reliability.

Closest to the proposed technical solution is a method of manufacturing polystyrene concrete products from a composition containing Portland cement, granular foamed polystyrene, reinforcing material, an air-entraining additive resin-wood saponified, a plasticizing additive and water, including supplying to the concrete mixer a calculated amount of granulated foamed polystyrene with water mixing while mixing, the introduction of cement, the remainder of the mixing water, air entrainment and ifitsiruyuschey additives, stirring the mixture, molding and heat treatment, wherein the use composition comprising, in weight.%:

portland cement 68-90

polystyrene foam 0.7-2.3

saponified wood resin

(on dry matter) 0.3-0.7

plasticizer

(on dry matter) 0.25-0.55

water rest

reinforcing material 1.4-5.2

The disadvantage of the method of the known composition is the following:

the use of fibrous materials worsens the sanitary conditions of production, since the fibers increase the dust content of the air of the working area;

uneven distribution of the components of the mixture among themselves due to their simultaneous mixing in the concrete mixer;

use of toxic formaldehydes and phenols in the technology;

the need to use thermal energy for heat treatment of molded products;

the use of the following components as reinforcing material:

- cellulose, swelling in water [2] and contributing to additional shrinkage in the manufacture of products;

- vermiculite (highly hydrated mica with a content of Fe ₂ O ₃ + FeO 5-17%, H ₂ O 8-18%), which is represented by plate crystals in a bulk of less than 3 mm, 50% less than 1 mm, density 2.05-2 , 71 g / cm ³ , expansion at a temperature of 150-300 ° C [3], iron oxides of which contribute to the electrochemical corrosion of embedded metal structures, expansion of vermiculite can destroy products at temperatures above 150 ° C;

- mineral and glass fibers having a diameter of 1 to 12 μm, a length of 2-50 mm, which, firstly, it is almost impossible to evenly distribute in the mixture and, secondly, during the mixing, the fibers are destroyed (shortened, split), which collectively leads to a decrease in the strength of the finished product;

- the fine fraction of polystyrene aggregate causes a higher bulk density of finished products (850-1120 g / cm ³ ), which leads to an increase in their thermal conductivity coefficient (0.2-0.22) W / (m · ° C), i.e. . to reduce the thermal insulation properties of products;

- inefficient use of reinforcing materials associated with their anisotropic distribution over the volume of the product, since the used short fibers and small particles cannot be oriented in horizontal and vertical position when mixing the mass in the mixer. This leads to increased consumption of cement, an increase in the bulk density of polystyrene concrete products, which limits their transportability.

The aim of the invention is to remedy these disadvantages.

This is achieved by the fact that, in contrast to the known method of manufacturing polystyrene concrete products from a composition containing Portland cement, granular foamed polystyrene, reinforcing material, an air-entraining additive-resin wood saponified, a plasticizing additive and water, including the supply of a calculated amount of granulated foamed polystyrene to the concrete mixer, wetting part of the mixing water with stirring, the introduction of cement, the remaining part of the mixing water, air entrainment and plasticizing to grain, mixing the mixture, molding the products and their heat treatment, in the present invention, the air-entraining additive-wood-saponified resin is preliminarily diluted with water in the ratio (1: 5) - (1:10) to 8-12% dry matter concentration and can withstand 48 hours at a temperature of 15-35 ° C. to wet the granular foamed polystyrene having a bulk density of 25-30 kg / m (fractions with a diameter of 3-5 mm), use 1/3 of the mixing water, and mix for 0.5-1.5 minutes, after adding Portland cement to the mixer 400-500 grades, the mixture is stirred for 30-60 seconds, then the remaining 2/3 parts of mixing water, pre-diluted saponified wood resin and plasticizing additive - lignosulfonate or C3 superplasticizer are fed into the mixer, the mixture is stirred for at least 2 minutes and heated due to the heat of hydration of the cement enth to a temperature of 35-75 ° C and to obtain a cohesive porous homogeneous structure, during molding, the prepared polystyrene-concrete mixture is fed using a vise pump into the formwork with a mesh frame made of reinforcing material-threads or rods with a diameter of (0.5-3) d, cell (5-100) · (50-100) d in 2-4 layers and connecting transverse rods with a diameter of (1.0-4) d in increments of (100-200) · (100-200) d, where d is the average diameter of polystyrene granules. moreover, the protective layer between the reinforcement and the outer surface is at least 25 mm. the laid mixture is leveled and kept at a temperature of 15-35 ° C for at least 12 hours, on the resulting polystyrene concrete product, after its removal, spray water once every three days for 30 days, starting from the 8th day after laying the mixture in the formwork, using a composition including, wt.%:

portland cement 68-70

expanded polystyrene 3-6

saponified wood resin

 (per dry matter) 0.02-0.1

plasticizer

(on dry matter) 0.1-0.2

water rest

reinforcing material

(over 100%) 5-12

Technical result: the proposed method of manufacturing polystyrene concrete products eliminates the disadvantages of the prototype, reduces bulk density to 500-800 kg / m ³ and thermal conductivity - to 0.11-0.17 W / (m · ° C), reduces the consumption of foamed polystyrene, mineral binder toxic in manufacture and use

air-entraining additives, while ensuring the transportability and thermal protection of polystyrene concrete products.

When foamed polystyrene granules are mixed with part of the mixing water, water penetrates into the pores and capillaries of the polystyrene granules and prevents the penetration of air-entraining additives, which would otherwise be adsorbed in the pores and capillaries and thereby increase the bulk density of the granules and the thermal conductivity of the products. When preparing an aqueous solution of an air-entraining additive at temperatures of 15-35 ° C, its gelation occurs (transition to a colloidal state). After the introduction of the remaining components during the mixing process, the hydration of the cement occurs with the release of a significant amount of heat and the gelation of an aqueous solution of lignosulfonate. At elevated temperatures (35-75 ° C) and subsequent exposure of the mixture, the surfaces of the expanded polystyrene granules are wetted with a gelatinized air-entraining additive and lignosulfonate or C3 superplasticizer, their interaction at the molecular level with the surface of the polystyrene granules, which leads to their hardening. In the process of joint mixing of the moistened components of the charge, calcium hydrosilicates are formed in the mixers, which, partially in the colloidal state, interact with the gelled (colloidal) air-entraining additive and the lignosulfonate or superplasticizer C3, which gives the mass cohesion and formability. Cement dough, colloidal air-entraining additives and lignosulfonate or superplasticizer C3 contribute to the adhesion of thin grains of cement to large polystyrene granules, and thereby the homogenization of the mass. This allows to reduce the consumption of mineral binders, air-entraining and plasticizing additives by 1.5-2 times and harmful emissions into the environment.

When mixing the mass, a uniform distribution of the components over its entire volume occurs. Fine particles of cement are connected by colloidal micelles of air-entraining and plasticizing additives and, unlike the prototype, do not migrate to the surface of the product, therefore, after a day in the product there is guaranteed bonding of polystyrene granules with concrete, which increases the uniformity of the properties of the product throughout their entire volume. This is also facilitated by regular wetting of the surface of the products with water.

The achievement of the technical result in the implementation of the totality of the features of the invention set forth in the formula is confirmed by the following example:

- an air-entraining additive-resin wood saponified SDO, meeting the requirements of TU 13-0281-078-02-93, is preliminarily diluted with water that meets the requirements of GOST 23732, in a ratio of 1:10 to 10% concentration on dry matter and can withstand up to 48 hours at a temperature of 15-20 ° C;

- granular foamed polystyrene having a bulk density of 25-30 kg / m ³ with fractions of a diameter of 3-5 mm, is mixed in the mixer for 1 minute with 1/3 of the mixing water:

- the blended Portland cement grade M 400 that meets the requirements of GOST 10178 is loaded into the mixer, and the mixture is mixed for 30 seconds,

- then the remaining 2/3 of the mixing water, 10% solution of air-entraining additives, 10% solution are poured into the mixer

saponified wood resins and plasticizing additive (lignosulfonate or superplasticizer C3);

- the mixture is mixed for at least 2 minutes and warmed up due to the heat of hydration of the cement to a temperature of 35 ° C and obtaining a cohesive porous homogeneous structure;

- the prepared polystyrene concrete mixture is fed using a vise pump into the formwork with 08A3 reinforcement installed in it with a 200 × 200 mm mesh in 2 layers and the installation of connecting transverse rods with a pitch of 400 × 400 mm. The protective layer between the reinforcement and the outer surface of the polystyrene concrete must be at least 25 mm;

- after laying, the mixture is leveled and kept at a temperature of 15-20 ° C for at least 12 hours;

after stripping onto polystyrene concrete products, water is sprayed from a paint gun once every three days for 30 days, starting from the 8th day after pouring the mixture into the formwork.

The compositions of the manufactured products are shown in the table.

An analysis of the information showed that the claimed technical solution is not known from the achieved level of technology, and therefore it meets the criterion of "novelty."

Such a technical solution does not explicitly follow from the prior art and, therefore, meets the criterion of “inventive step”.

The foregoing indicates that the invention meets the criterion of "industrial applicability".

Uromgaz LLC manufactured and tested pilot batches of block boxes of gas distribution stations from polystyrene concrete products in which the claimed solution is implemented.

The positive test results for polystyrene concrete products at the metallurgical, engineering, and gas industries have confirmed their effectiveness and widespread practical use in the future.

Sources of information

1. Patent No. 2150446, cl. C 04 V 38/08, C 04 V 38/10 dated 01.12.1998 (prototype).

2. Bratsykhin. B.A. Technology of plastics. - L .: Chemistry, 1974, p. 308.

3. Building materials. Directory. - M.: Stroyizdat, 1989, p. 20.

Claims (1)

A method of manufacturing polystyrene concrete products from a composition containing Portland cement, granular foamed polystyrene, reinforcing material, an air-entraining additive - saponified wood resin, plasticizing additive and water, comprising supplying a calculated amount of granular foamed polystyrene to the concrete mixer, wetting it with part of the mixing water, mixing with mixing the remainder of the mixing water, air-entraining and plasticizing additives, mixing the mixture, molding products and their heat treatment, characterized in that the air-entraining additive - saponified wood resin is pre-diluted with water in a ratio of (1: 5) - (1:10) to an 8-12% concentration on a dry matter basis and kept for up to 48 hours at a temperature of 15-35 ° C, to wet the granular foamed polystyrene having a bulk density of 25-30 kg / m ³ fractions with a diameter of 3-5 mm, use 1/3 of the mixing water and mix for 0.5-1.5 minutes, after introduction into 400-500 Portland cement mixer the mixture is stirred for 30-60 s, then the remaining 2/3 is fed into the mixer Part of mixing water, pre-diluted saponified wood resin and plasticizing additive - lignosulfonate or C3 superplasticizer, the mixture is stirred for at least 2 min and heated by the heat of hydration of the cement to a temperature of 35-75 ° C and obtaining a coalesced porous homogeneous structure, when molding the prepared polystyrene concrete mixture is fed using a screw pump into the formwork with a honeycomb frame made of reinforcing material — threads or rods with a diameter of (0.5-3) d, with a cell (50-100) x (50-100) d in 2-4 layers and a bond with transverse rods with a diameter of (1.0-4) d with a step of (100-200) x (100-200) d, where d is the average diameter of polystyrene granules, and the protective layer between the reinforcement and the outer surface is at least 25 mm, laid the mixture is leveled and kept at a temperature of 15-35 ° C for at least 12 hours, on the resulting polystyrene concrete product, after its removal, spray water once every three days for 30 days, starting from 8 days after laying the mixture in the formwork, while using composition, including, wt.%: Portland cement 68-70 Foamed polystyrene 3-6 Saponified wood resin (dry matter) 0.02-0.1 Plasticizing additive (dry matter) 0.1-0.2 Water Else Reinforcing material (over 100%) 5-12