RU2763568C1 - Composition for producing polystyrene concrete, method of its production and monolithic block - Google Patents

Abstract

FIELD: building materials.

SUBSTANCE: invention relates to the production of porous building materials, in particular lightweight concrete. The specified technical result is achieved due to the fact that the composition for the manufacture of expanded polystyrene concrete includes polystyrene granules, water, cement grade D0 (M500), sand, characterized in that it additionally contains an aqueous solution of sodium silicate in a ratio of 1:10, as well as wood resin saponified in the form of a 10% aqueous solution. Also described is a method for producing expanded polystyrene concrete and a monolithic block made in this way.

EFFECT: reducing material consumption, reducing the time of construction and finishing work, improving sound insulation, eliminating the need to use additional heaters while maintaining thermal conductivity resistance, reducing moisture absorption, increasing concrete strength and resistance to dynamic loads.

4 cl

Description

The invention relates to the production of porous building materials, in particular lightweight concrete [MPK C04B 38/00, C04B 38/10, C04B 40/00, SEC C04B 38/08, C04B 38/10].

The prior art known METHOD OF MANUFACTURING THERMAL INSULATION PRODUCTS [RU2254310, publ. 06/20/2005], in which portland cement grade 400-500, expanded polystyrene granulated PVG grade by bulk density 10-20 kg/m foamed PVG for 2-3 minutes, then water containing superplasticizer C-3 is added, mixed for 3-5 minutes, the mixture is loaded into molding boxes, molding is carried out by vibration compaction and pressing, followed by the removal of products from molding boxes before heat treatment, which is carried out in the following mode: 2 hours at a temperature of 15-25°C, then 8 hours at 40-60°C and 1 hour at 15-30°C, with the following ratio of components, wt.%: specified Portland cement 60.0-65.6 , microsilica 6.6-12.0, the specified PVG 2.2-4.4, superplasticizer C-3 0.6-0.66, water - the rest. EFFECT: obtaining heat-insulating products characterized by reduced cement consumption, improved workability, formability, increased strength and productivity.

The disadvantage of analogue is the absence of an air-entraining additive, such as saponified wood resin, which leads to an increase in the density of the material and does not allow achieving high strength indicators.

Known from the prior art REINFORCED POLYSTYRENE CONCRETE MIXTURE, METHOD FOR PREPARING MIXTURES, METHOD FOR MANUFACTURING HEAT-INSULATING PRODUCTS, PANEL AND BLOCK (OPTIONS) [RU2309134, publ. 27.10.2007], the composition of the mixture includes (kg / m ³ ): Portland cement - 160-170, expanded granular polystyrene - 15-17, basalt fiber - 0.50-0.70, saponified wood resin - 0.35-0 .50, plasticizing additive - C-3 - 1.50-2.50, water-repellent additive - 0.4-0.5, polyacrylamide - 0.40-0.60, lignopan B-2 - 0.35-0, 50, water - 50-55. The method for preparing a reinforced polystyrene concrete mixture includes mixing the components of the composition to obtain it. At the same time, expanded polystyrene, basalt fiber and additives introduced together with part of the mixing water are pre-mixed. Then Portland cement is added with stirring, stirring is continued for 5-15 seconds, after which water is added and mixed for 25-40 seconds. The manufacture of products from polystyrene concrete mixture is carried out by volumetric vibrocompression with a compaction value of 8-15 kg/cm2. The technical result consists in simplifying the method of preparing the mixture, high strength products, improved thermal insulation properties, high frost resistance, low vapor permeability and low water absorption.

The disadvantage of the analog is the low (less than 1 wt.%) content of saponified wood resin, which reduces the entrainment of a sufficient amount of air into the mixture and ultimately leads to weighting of the finished block and waste of material. Also, the disadvantages include an increased (more than 3 wt.%) content in the mixture of polystyrene granules, which requires additional protection from moisture (except for water-repellent additives), as well as the application of an additional protective coating (plastering, priming), in order to avoid a decrease in strength under conditions regular temperature changes (freezing and thawing).

The prior art known METHOD OF MANUFACTURING POLYSTYRENE CONCRETE PRODUCTS [RU2223931, publ. 02/20/2004], in which the air-entraining additive - saponified wood resin - is preliminarily diluted with water in the ratio (1:5) - (1:10) to 8-12% concentration on dry matter and kept up to 48 hours at a temperature of 15- 35°C. For wetting granular expanded polystyrene having a bulk density of 25-30 kg/m3, fractions with a diameter of 3-5 mm, use 1/3 of the mixing water and mix for 0.5-1.5 minutes. Portland cement mixer brand 400-500 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 by heat hydration of cement to a temperature of 35-75°C and obtaining a continuous porous homogeneous structure. During molding, the prepared polystyrene concrete mixture is fed using a screw pump into the formwork with a cellular frame made of reinforcing material installed in it - threads or rods with a diameter of (0.5-3) d, with a cell of (50-100) x (50-100) d in 2-4 layers and connecting transverse rods with a diameter of (1.0-4) d with a pitch of (100-200)x(100-200) d, where d is the average diameter of polystyrene granules. The protective layer between the reinforcement and the outer surface is at least 25 mm. The laid mixture is leveled and maintained at a temperature of 15-35°C for at least 12 hours. On the resulting polystyrene concrete product, after its stripping, water is sprayed 1 time in three days for 30 days, starting from the 8th day after laying the mixture in the formwork. Use the composition, including, wt.%: Portland cement 68-70; expanded polystyrene 3-6; saponified wood resin (per dry matter) 0.02-0.1; plasticizing additive (on dry matter) 0.1-0.2; water - the rest, reinforcing material (over 100%) 5-12. EFFECT: reduced bulk density and thermal conductivity of products, reduced consumption of initial components.

The disadvantage of the analogue is an increased (more than 3 wt.%) content in the mixture of polystyrene granules, which requires additional protection from moisture (except for water-repellent additives), as well as the application of an additional protective coating (plastering, priming), in order to avoid strength reduction in conditions of regular drops temperatures (freezing and thawing). Also, the disadvantages include the absence of sand in the composition, with the help of which, with a gradient fill, it is possible to perform the front part of the concrete wall.

The closest in technical essence is RAW MIXTURE FOR MASONRY MORTAR AND METHOD FOR ITS MANUFACTURE [RU 2490233, publ. 20.08.2013], which contains, wt.%: Portland cement 18.76-20.70, quartz sand with the largest grain size 2.5 and fineness modulus 2.37 56.29-62.10, expanded polystyrene waste, crushed to granules size 2-7 mm, bulk density 38-40 kg / m3, modified 0.25-0.56, liquid soda glass with a density of 1250 kg / m3 0.415-0.9296, fly ash from the combustion of brown coal 4.14-9 ,38, water - the rest. A method for manufacturing a masonry mortar from the above raw mixture includes crushing waste foam polystyrene to granules of a specified size and density, feeding the obtained granules into a mortar mixer, adding the specified liquid glass with water in a ratio by weight of 1:1, mixing for 1-2 minutes, introducing the specified fly ash and mixing for 1-3 minutes, the introduction of portland cement, the specified sand and the rest of the water into the mortar mixer with the specified waste foam polystyrene, the specified sand and the rest of the water and mixing for 3-5 minutes. EFFECT: obtaining masonry mortar with reduced density and thermal conductivity of grades M25-M100.

The main technical problem of the prototype is a low (less than 2 wt.%) content of polystyrene granules and cement in combination with a high (more than 25 wt.%) content of quartz sand, which increases the density and mass of the finished product and can lead to a decrease in noise and heat insulation and strength of concrete, as well as an increase in moisture absorption. At the same time, the increased content of quartz sand does not allow, if necessary, to obtain a monolithic block with different body densities, when the highest density is formed precisely in the front part, where a large amount of heavy filler - sand is concentrated, and the lowest density - in the back part, where a large number of light polystyrene granules.

The objective of the invention is to eliminate the disadvantages of the prototype.

The technical result of the invention is to reduce material consumption, reduce the time of construction and finishing work, improve sound insulation, eliminate the need for additional insulation while maintaining thermal conductivity, reduce moisture absorption, increase concrete strength and resistance to dynamic loads.

This technical result is achieved due to the fact that the composition for the manufacture of expanded polystyrene concrete, including polystyrene granules, water, cement brand D0 (M500), sand, characterized in that it additionally contains an aqueous solution of sodium silicate according to GOST 13078-81 in a ratio of 1:10, as well as saponified wood resin in the form of a 10% aqueous solution, with the following ratio of components, wt.%:

polystyrene granules 2-3 cement brand D0 (M500) 69-72 sand 15-25 aqueous solution of sodium silicate according to GOST 13078-81 in a ratio of 1:10 1.8-2.5 saponified wood resin in the form of a 10% aqueous solution 1.2-1.6 water rest

This technical result is achieved due to the fact that the method for producing expanded polystyrene concrete according to claim 1, including loading polystyrene granules into a mechanical concrete mixer, adding water to the mixture, adding cement to the mixture and mixing until a homogeneous mass for 1 minute, adding sand to the mixture and mixing to a homogeneous mass within 1 minute, characterized in that after loading polystyrene granules into a mechanical concrete mixer and adding water, an aqueous solution of sodium silicate is additionally added to the mixture and mixed for 1-2 minutes, then saponified wood resin is added to the mixture, then it is filled after the preparation of the mixture, pre-prepared forms with facade matrices placed at the bottom, after which the filled forms are vibrated for 10-15 seconds, each form is manually hatched to remove air bubbles from the walls of the finished product, the mixture is heated in the forms in the heating chambers for 1-2 hours to a temperature of 60-80°C, the finished material is cooled down for 4-5 hours, the finished material is removed from the molds and the front part is treated with a deep-penetrating primer, after which the finished material is packed in a plastic film and settling is carried out for 2 days.

The specified technical result is achieved due to the fact that a monolithic block manufactured by the method according to claim 2, characterized in that it is made with a gradient density of the body, while the highest density is in the front part, and the lowest density is in the back part.

Implementation of the invention.

The composition for the manufacture of expanded polystyrene concrete includes polystyrene granules, water, cement brand D0 (M500), sand, an aqueous solution of sodium silicate (liquid glass) according to GOST 13078-81 in a ratio of 1:10, as well as saponified wood resin in the form of a 10% aqueous solution, with the following ratio of components, wt.%:

polystyrene granules 2-3 cement brand D0 (M500) 69-72 sand 15-25 aqueous solution of sodium silicate according to GOST 13078-81 in a ratio of 1:10 1.8-2.5 saponified wood resin in the form of a 10% aqueous solution 1.2-1.6 water rest

When implementing the proposed method for the manufacture of expanded polystyrene ^{concrete, to obtain 1 m 3 of the} finished mixture weighing 600 kg, the required amount (about 80% of the volume of the final mixture, 2-3% by weight of the mixture) of polystyrene granules is loaded into a mechanical concrete mixer, the required amount of water is poured (15- 25% by weight of the mixture) and an aqueous solution of sodium silicate (according to GOST 13078-81, a solution in a ratio of 1:10 with water, in an amount of 1.8-2.5% by weight of the mixture) as a surfactant for coating granules polystyrene. Mixing occurs until the granules are completely wetted (1-2 minutes), after which cement grade D0 (M500) is added to the mixture (in the amount of 69-72% by weight of the mixture). Mixing occurs until a homogeneous mass is formed (1 minute), after which sand is added (in an amount of 15-25% by weight of the mixture), mixing again until a homogeneous mass (1 minute), the last component is added saponified wood resin (10% solution in an amount of 1.2-1.6% by weight of the mixture), which actively entrains air into the resulting mixture and increases the volume of the mixture to the planned one.

After the preparation of the mixture, pre-prepared molds are filled with steel or polyurethane facade matrices placed at the bottom, while the molds are filled with excess, that is, with excess of the upper level. The filled molds are vibrated for 10-15 seconds in order to precipitate a heavy fraction of sand on the facade matrices, and are subjected to “hatching” - the worker manually, with a special probe, draws along the contour of each mold in order to remove air bubbles formed during vibration from walls of the finished product. Forms are placed on movable trolleys, and after filling and carrying out all the work, they are moved to the heating chambers.

In the heating chambers, the mixture in the molds is heated up to 60-80°C for 1-2 hours in order to stop the process of settling the heavy fraction of the mixture and speed up the process of concrete hydration. After 4-5 hours, the molds are disassembled, the finished material is removed, the facade part is treated with a deep-penetrating primer and placed on pallets, where it is packed in a film and settled for another two days.

The claimed technical solution is used in the construction of walls with a finished facade.

The claimed technical result is achieved through the use of light porous polystyrene granules and the use of saponified wood resin to entrain air (reduction in mass and moisture absorption, increase in heat and sound insulation, increase in strength and resistance to deformation), as well as through the use of sand in the mixture in an experimentally calculated quantity (15-25 wt.%), while the sequence and duration of the mixing, vibrating and heating processes indicated in the method provides a gradient density of the finished material, when the facade part has the highest density, which ensures that the finished facade wall is obtained without additional finishing work, which significantly reduces the consumption of materials, the cost of the finished product, reduces the total time required for construction and finishing work in the construction of buildings and structures.

An example of achieving a technical result.

To implement the proposed method, polystyrene granules were loaded into a mechanical concrete mixer in an amount of 2.5% by weight of the final mixture, water was poured in an amount of 20% by weight of the mixture and an aqueous solution of sodium silicate (1:10) in an amount of 2% by weight of the mixture. The solution was mixed for 1.5 minutes until the polystyrene granules were completely wetted, after which cement grade D0 (M500) was added to the mixture in an amount of 70% by weight of the mixture. Mixing was continued until a homogeneous mass was formed (for 1 minute), after which sand was added in an amount of 20% by weight of the mixture. The solution was mixed again until a homogeneous mass was obtained (within 1 minute), the last component was added saponified wood resin (10% solution in an amount of 1.4% by weight of the mixture).

After the preparation of the mixture, pre-prepared forms were filled with excess (“heaped”) with polyurethane facade matrices placed at the bottom, the filled forms were subjected to vibration for 13 seconds to deposit a heavy fraction of sand on the facade matrices, after which “hatching” was carried out to remove air bubbles along the contour of each form with a special probe. Placed molds are placed on movable trolleys and after filling placed in heating chambers, where within 1 h. 50 min. warmed up to 80 ° C. After 4 hours, the molds were dismantled, the finished material was removed from them, the front part was treated with a deep-penetrating primer, laid on pallets and packed in a film, where the finished material settled for two days.

The implementation of the proposed method made it possible to achieve the following characteristics of finished monolithic blocks:

Density, kg / m ³ 600 compressive strength, MPa 1.5-2.1 bending strength, MPa 0.35-0.9 thermal conductivity coefficient, W/mK 0.08-0.14 water absorption at full immersion,% by volume 0.8-1.2 vapor permeability, mg/m⋅h⋅Pa 0.64-0.78 strength loss at 100 times freezing down to -50°С, % 1.4-1.65.

Claims (4)

1. Composition for the manufacture of expanded polystyrene concrete, including polystyrene granules, water, cement brand D0 (M500), sand, characterized in that it additionally contains an aqueous solution of sodium silicate in a ratio of 1:10, as well as saponified wood resin in the form of 10% aqueous solution, with the following ratio of components, wt.%: polystyrene granules 2-3 cement brand D0 (M500) 69-72 sand 15-25 an aqueous solution of sodium silicate in a ratio of 1:10 1.8-2.5 saponified wood resin in the form of a 10% aqueous solution 1.2-1.6 water rest 2. The method for producing expanded polystyrene concrete according to claim 1, including loading polystyrene granules into a mechanical concrete mixer, adding water to the mixture, adding cement to the mixture and mixing until a homogeneous mass for 1 minute, adding sand to the mixture and mixing until a homogeneous mass for 1 minute , characterized in that after loading polystyrene granules into a mechanical concrete mixer and adding water, an aqueous solution of sodium silicate is additionally added to the mixture and mixed for 1-2 minutes, then wood saponified resin is added to the mixture, then after the mixture is made, pre-prepared molds with placed at the bottom with facade matrices, after which the filled forms are vibrated for 10-15 seconds, each form is manually hatched to remove air bubbles from the walls of the finished product, the mixture in the forms is heated in the heating chambers for 1-2 hours to a temperature of 60-80 ° C, carry out the cooling of the finished material for 4-5 hours, the finished material is removed from the molds and the front part is treated with a deep-penetrating primer, after which the finished material is packed in a plastic film and settling is carried out for 2 days. 3. A monolithic block manufactured by the method according to claim 2, characterized in that it is made with a gradient density of the body, while the highest density is in the front part, and the lowest density is in the back part.