RU2789473C1 - Mixture for manufacturing plates from foam polystyrene concrete - Google Patents

Abstract

FIELD: technical materials.

SUBSTANCE: invention relates to the field of technical materials, in particular to structural, heat-insulating, sound-proof plates made of expanded polystyrene concrete, namely, to a mixture for the manufacture of plates from expanded polystyrene concrete. The mixture for the manufacture of slabs of expanded polystyrene concrete includes, wt.%: Portland cement 47.3-66.0, ground granulated blast-furnace slag 5.0-7.0, silica fume 5.0-7.0, redispersible polymer powder 0.5-0 .7, expanded polystyrene 1.5-2.1, polycarboxylate superplasticizer 1.1-1.5, sand 0.0-28.3, water 11.3-15.7.

EFFECT: reducing the weight of the building board made from the claimed mixture, utilization of blast-furnace slag.

1 cl, 3 tbl

Description

The invention relates to the field of technical materials and, in particular, to structural, heat-insulating, sound-proof plates made of expanded polystyrene concrete, as well as mixtures and methods for manufacturing plates from expanded polystyrene concrete [C09D 175/00, C09D 115/00, C09D 109/00].

The prior art LIGHT-WEIGHT CONCRETE MIXTURE [RU2134673, publ. 20.08.1999] comprising cement, expanded polystyrene, disodium salt of ethylenediaminetetraacetic acid and water, characterized in that it contains, as an additive, benzosulfate of methyldiethylaminomethylmethacrylphenol polyglycol ether in the following ratio, wt.%: cement - 71.25 - 72.44; expanded polystyrene - 2.96 - 3.43; disodium salt of ethylenediaminetetraacetic acid - 0.01 - 0.15; benzosulfate of methyldiethylaminomethylmethacrylphenol polyglycol ether - 0.005 - 0.02; water is the rest.

Also known from the prior art is a METHOD FOR MANUFACTURING A REFRACTORY PLATE USING FOAM PARTICLES [KR101512443, publ. May 13, 2015]. The present invention relates to a refractory board using expanded polystyrene particles and a method for manufacturing a refractory board, namely, a refractory board using expanded polystyrene particles, which are formed by mixing and kneading crushed and expanded polystyrene foam.

Also known from the prior art is a METHOD FOR MANUFACTURING LIGHT-WEIGHT CONCRETE MIXTURE [RU2024564, publ. 15.12.2004] including mixing of expanded polystyrene granules, quartz sand, cement and a surface-active additive, characterized in that, in order to accelerate the set of strength during cold hardening, a viscous foam based on saponified wood resin is added to the mixture, and mixing is carried out by the sequential introduction of quartz sand, cement, 5% solution of surfactants, viscous foam based on wood saponified resin and expanded polystyrene in the following ratio, wt.%: cement 51-57; 5% solution of surfactants 4.1-4.8; viscous foam 15.5-18.7; expanded polystyrene granules 2.1-2.7; quartz sand - the rest.

The closest in technical essence is COMPOSITION FOR MANUFACTURING POLYSTYRENE CONCRETE MIXTURE [RU2150446, publ. 06/10/2000] including a mineral binder, a polystyrene filler, an air-entraining additive and water, characterized in that it additionally contains a fibrous material and a plasticizing additive, and as a polystyrene filler - a mixture of particles from foamed polystyrene granules of a fraction of 0.04 - 1.25 mm and particles of torn polystyrene fraction 0.04 - 1.63 mm at their mass ratio of 1: (8 - 12) in the following ratio, wt.%: mineral binder - 68 - 90; polystyrene filler - 0.7 - 2.3; fibrous material - 1.4 - 5.2; air-entraining additive - 0.3 - 0.7; plasticizing additive - 0.25 - 0.55; water is the rest.

The main technical problem of the above prototype and analogues is the large weight obtained from the above compositions and mixtures of products - concrete slabs. A large weight is justified by large proportions of heavy components such as cement, sand, etc.

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

The technical result of the invention is to reduce the weight of the building board.

The specified technical result is achieved due to the fact that the mixture for the manufacture of foam polystyrene concrete slabs, including Portland cement, expanded polystyrene, superplasticizer and water, characterized in that polycarboxylate superplasticizer is used as a superplasticizer, and additionally the mixture includes ground granulated blast-furnace slag, silica fume, redispersible sand polymer powder with the following ratio of components, wt.%:

Portland cement 47.3-66.0 ground granulated blast-furnace slag 5.0-7.0 microsilica 5.0-7.0 sand 0.0-28.3 redispersible polymer powder 0.5-0.7 polystyrene foam 1.5-2.1 polycarboxylate superplasticizer 1.1-1.5 water 11.3-15.7

Implementation of the invention.

A mixture for the manufacture of slabs of expanded polystyrene concrete with a density of 200 to 950 kg / m ³ includes the following components, wt.%:

Portland cement 47.3-66.0 ground granulated blast-furnace slag 5.0-7.0 microsilica 5.0-7.0 sand 0.0-28.3 redispersible polymer powder 0.5-0.7 polystyrene foam 1.5-2.1 polycarboxylate superplasticizer 1.1-1.5 water 11.3-15.7

Microsilica is an ultradispersed material consisting of spherical particles obtained in the process of gas cleaning of technological furnaces in the production of silicon and ferrosilicon. The main component of the material is amorphous silicon dioxide. Instead of microsilica, metakaolin can be used, which is an aluminosilicate - an artificial powdery material, a product of roasting (dehydration) with subsequent grinding of enriched kaolin clays.

A redispersible powder is a polymer capable of redispersing when mixed with water, i.e. re-form aqueous polymer dispersions, which, as a result of curing, form a continuous polymer film. The redispersible powder contributes to high water-holding capacity, adhesion and workability of dry mortars.

Expanded polystyrene is a gas-filled material obtained from polystyrene and its derivatives, as well as from styrene copolymers, is a widespread type of foam. The technology for producing expanded polystyrene is associated with the initial filling of styrene granules with gas, which is dissolved in the polymer mass. Subsequently, the mass is heated with steam. In the process of this, a multiple increase in the volume of the initial granules occurs until they occupy the entire block-form and sinter together.

Polycarboxylate superplasticizer is a polymer and is intended for the production of dry mixes of mortars and concrete. The polycarboxylate superplasticizer contributes to a significant reduction in water, increasing the flowability of the mixture, and at the same time, provides optimal cohesion and maximum self-compacting.

A polycarboxylate superplasticizer is included in the mixture to ensure that the required strength of the final material is obtained, as well as its durability. The percentage ratio of 1.1-1.5% is justified by the fact that at lower dosages the effectiveness of the superplasticizer decreases and this leads to an increase in cement consumption and an increase in cost, and at high dosages the efficiency of the superplasticizer decreases, leading to an increase in cost, and the viscosity of concrete also increases. . At higher dosages of polycarboxylate superplasticizer, the manufacturability of production decreases and the number of rejects increases due to the fact that ultra-precise control of water is required, which is difficult to implement in production conditions due to the constantly unevenly changing natural moisture content in materials.

Instead of ground granulated blast-furnace slag, fly ash or limestone (dolomite) flour can be used.

The components of the composition for the manufacture of slabs of expanded polystyrene concrete are selected in accordance with the requirements of GOST, namely:

- cement CEM I 42.5 and CEM 0 42.5 - GOST 31108;

- ground granulated blast-furnace slag - GOST 3476, fly ash - GOST 25818, - limestone dolomite flour GOST - 14050;

- microsilica - GOST R 58894, metakaolin - GOST R 59536;

- sand - GOST 8736;

- redispersible powder - GOST 24211;

- polycarboxylate superplasticizer - GOST 24211;

- water - GOST 23732;

- expanded polystyrene - GOST 15588.

The method for producing a mixture for expanded polystyrene concrete includes the following steps:

- the required volume of expanded polystyrene is poured into the mixer;

- cement and ground granulated blast-furnace slag are poured into the mixer;

- carry out uniform mixing for at least 10 seconds;

- the necessary volume of "mixing" water is dosed into the mixer together with polycarboxylate superplasticizer and redispersible powder;

- carry out uniform mixing for at least 120 seconds.

In finished form, the temperature of the concrete mix should be between +5 ^o C and up to +30 ^o C.

The use of dry chemical additives in the composition of the foam polystyrene concrete mixture ensures high adhesion between the components of the mixture and the uniformity of the foam polystyrene concrete mixture.

Also, the claimed technical solution allows to reduce the amount of cement while maintaining the necessary physical and mechanical properties of the manufactured panels.

The selected recipe makes it possible to produce plates from the mixture described above and achieve the requirements for thermal insulation, sound insulation, fire resistance, which are imposed by SNiP, GOST and SaNPiN for elements of residential, industrial and public buildings.

A slab made on the basis of a mixture for expanded polystyrene concrete is a one, two or three-layer structure. The main layer is the above-described mixture of expanded polystyrene concrete, obtained as a result of the implementation of the above method. Facing sheets on each side can act as additional layers of the slab.

The cladding sheet is a 2mm to 10mm thick sheet based on glass-magnesium sheet, calcium silicate, perlite, fiberglass, inorganic fiber, white cement, or any other sheet that provides the necessary requirements for the cladding layer for a particular panel. The panels are interconnected face to face using adhesive or masonry mortars. To connect the panels to each other, they can also use a tongue-and-groove connection, to give additional rigidity and solidity to the wall formed by means of the plates, and also eliminates cold bridges.

There are various options for manufacturing panels from the claimed mixture.

In particular, it is possible to manufacture panels from expanded polystyrene concrete in the form of a parallelepiped of the following size range (as well as L, P, W, T, H shaped panels inscribed in the parallelepiped, as well as triangles, hexagons, octagons and circles inscribed in the indicated dimensions):

- height from 300 mm to 3000 mm;

- width from 300 mm to 9000 mm;

- Including dimensions:

- 50 × 610 × 2270, 2440, 2680, 3000 mm;

- 60 × 610 × 2270, 2440, 2680, 3000 mm;

- 75 × 610 × 2270, 2440, 2680, 3000 mm;

- 90 × 610 × 2270, 2440, 2680, 3000 mm;

- 100 × 610 × 2270, 2440, 2680, 3000 mm;

- 120 × 610 × 2270, 2440, 2680, 3000 mm;

- 150 × 610 × 2270, 2440, 2680, 3000 mm;

- 180 × 610 × 2270, 2440, 2680, 3000 mm;

- 220 × 610 × 2270, 2440, 2680, 3000 mm;

- 240 × 610 × 2270, 2440, 2680, 3000 mm;

- 250 × 610 × 2270, 2440, 2680, 3000 mm;

- 260 × 610 × 2270, 2440, 2680, 3000 mm;

- 270 × 610 × 2270, 2440, 2680, 3000 mm;

- 280 × 610 × 2270, 2440, 2680, 3000 mm;

- 320 × 610 × 2270, 2440, 2680, 3000 mm;

- 350 × 610 × 2270, 2440, 2680, 3000 mm;

- 380 × 610 × 2270, 2440, 2680, 3000 mm;

- 400 × 610 × 2270, 2440, 2680, 3000 mm;

- 420 × 610 × 2270, 2440, 2680, 3000 mm;

- 450 × 610 × 2270, 2440, 2680, 3000 mm;

- 480 × 610 × 2270, 2440, 2680, 3000 mm;

- 50 × 1200 × 2270, 2440, 2680, 3000 mm;

- 60 × 1200 × 2270, 2440, 2680, 3000 mm;

- 75 × 1200 × 2270, 2440, 2680, 3000 mm;

- 90 × 1200 × 2270, 2440, 2680, 3000 mm;

- 100 × 1200 × 2270, 2440, 2680, 3000 mm;

- 120 × 1200 × 2270, 2440, 2680, 3000 mm;

- 150 × 1200 × 2270, 2440, 2680, 3000 mm;

- 180 × 1200 × 2270, 2440, 2680, 3000 mm;

- 220 × 1200 × 2270, 2440, 2680, 3000 mm;

- 240 × 1200 × 2270, 2440, 2680, 3000 mm;

- 250 × 1200 × 2270, 2440, 2680, 3000 mm;

- 260 × 1200 × 2270, 2440, 2680, 3000 mm;

- 270 × 1200 × 2270, 2440, 2680, 3000 mm;

- 280 × 1200 × 2270, 2440, 2680, 3000 mm;

- 320 × 1200 × 2270, 2440, 2680, 3000 mm;

- 350 × 1200 × 2270, 2440, 2680, 3000 mm;

- 380 × 1200 × 2270, 2440, 2680, 3000 mm;

- 400 × 1200 × 2270, 2440, 2680, 3000 mm;

- 420 × 1200 × 2270, 2440, 2680, 3000 mm;

- 450 × 1200 × 2270, 2440, 2680, 3000 mm;

- 480 × 1200 × 2270, 2440, 2680, 3000 mm.

In particular, if necessary, it is allowed to reinforce panels with metal or composite reinforcement with a diameter of 6 to 18 mm and / or mesh.

In particular, it is possible to manufacture L-shaped panels from expanded polystyrene concrete in a horizontal section, of the following size range:

- height from 300 to 3000 mm;

- side width from 300 to 1500 mm;

- thickness from 50 to 450 mm.

In particular, it is possible to manufacture panels from expanded polystyrene concrete for the manufacture of floor slabs and ceiling panels with reinforcement with reinforcement 6-18 mm thick and / or mesh, of the following size range:

- length from 1000 to 9000 mm;

- width from 300 to 3000 mm;

- thickness from 100 to 700 mm.

In particular, it is possible to manufacture panels from expanded polystyrene concrete for the manufacture of structural blocks of the following sizes:

- height from 100 to 500 mm;

- width from 200 to 1500 mm;

- thickness from 50 to 480 mm.

In particular, it is possible to manufacture panels from expanded polystyrene concrete for the manufacture of structural mega-blocks of the following sizes:

- height from 500 to 1000 mm;

- width from 1500 to 3000 mm;

- thickness from 50 to 480 mm.

In particular, it is possible to manufacture panels from expanded polystyrene concrete for the manufacture of window and door lintels using reinforcement with reinforcement with a thickness of 6-12 mm.

In particular, the following options for obtaining products from expanded polystyrene concrete are possible:

- casting in vertical matrices;

- casting in vertical cassette matrices;

- casting in horizontal matrices;

- casting into the formwork on the finished foundation;

- mold casting;

- casting into molds with subsequent cutting to the required dimensions;

- casting in vertical moulders.

Slabs made on the basis of a mixture for expanded polystyrene concrete are produced according to the technical specifications of TU and belong to the class of non-combustible materials.

Slabs made on the basis of a mixture for expanded polystyrene concrete comply with fire safety regulations with a fire resistance limit of EI 180, EI 240, i.e., thus, they can be used as fire partitions in buildings and structures of almost any fire hazard class.

Slabs made on the basis of a mixture for expanded polystyrene concrete have an expert opinion on compliance with unified sanitary, epidemiological and hygienic requirements, which allows the use of this material for the construction of residential, public and industrial buildings with the most stringent hygiene and environmental requirements, as well as in the construction of children's and preschool institutions.

According to the complex of technical and economic indicators, slabs made on the basis of a mixture for expanded polystyrene concrete correspond to all structural construction schemes.

The technical result of the invention - reducing the weight of the building board, is achieved due to the fact that the mixture for the manufacture of plates from expanded polystyrene concrete includes the above-described components with a percentage of mass. The presence of expanded polystyrene, as one of the main components of the mixture, provides a significant reduction in the weight of the produced plates, while maintaining high performance in terms of thermal insulation, sound insulation, moisture resistance, fire resistance, seismic resistance and durability. The use of ground granulated blast-furnace slag makes it possible to achieve the required characteristics in terms of wear resistance, reduce the weight of the slab and increase the indicators of heat and moisture insulation. The use of microsilica makes it possible to achieve optimal strength, hydrophobic and anti-corrosion properties of the manufactured board. The use of sand makes it possible to ensure the volume and interaction of the remaining components of the mixture and to ensure the distribution of stresses in the finished slab. The redispersible powder is used to harden the solution and acts as a binder, i.e. during the drying or setting process, it holds pigments and fillers together, increasing adhesion to the base. A polycarboxylate superplasticizer is used to increase the strength of the final material as well as its durability. Also, the claimed technical result is justified by the reduced percentages of the use of such components of the composition as: cement and water. Specific mass ratio. percent of the ingredients of the mixture for the manufacture of foam polystyrene concrete slabs is substantiated by the conducted studies and obtained experimentally.

The above ratios of the masses. percent allows to reduce the weight of walls and partitions formed from slabs, while meeting the requirements for thermal insulation, sound insulation, fire resistance, which impose SNiP, GOST and SaNPiN to elements of residential, industrial and public buildings.

Also, the claimed technical result of the invention - reducing the weight of the building slab, is achieved due to the fact that in the building slab the mixture for the manufacture of slabs of expanded polystyrene concrete, obtained according to the description method, acts as the main layer. At the same time, in addition to the main layer, a slab made on the basis of a mixture for expanded polystyrene concrete can have additional outer layers formed by facing sheets on each side.

Also, the claimed technical solution allows:

- reduce the thickness of walls and partitions, which leads to an increase in the area of \u200b\u200bthe room and a decrease in the volume of material;

- significantly reduce the load on foundations and supporting structures;

- use lifting equipment or small-scale mechanization of less power when installing walls;

- reduce the need for labor during construction;

- increase the speed of construction of objects;

- reduce the material consumption of construction;

- increase the fire resistance of the structure;

- improve seismic resistance.

An example of achieving a technical result.

The compositions of mixtures of plates made of expanded polystyrene according to the claimed method and according to the prototype method are shown in table 1.

Table 1. Name of components Declared solution (wt.%) Prototype (wt%) Portland cement - 47.3 68 ground granulated blast-furnace slag - 5.0 7 microsilica - 5.0 sand - 28.3 redispersible polymer powder - 0.5 expanded polystyrene - 1.5 2.3 polycarboxylate superplasticizer - 1.1 water - 11.3 16.55 fibrous material (cellulose) - 5.2 air-entraining agent - 0.7 plasticizer - 0.25

The results of testing samples of boards made from the above mixtures are presented in tables 2, 3.

table 2 Specifications Claimed Solution Strength - - 2.4 MPa 28 days. Thermal conductivity - - 0.145 W / (m × ^o C) Vapor permeability - - 0.068 capacity, mg / (m × h × Pa) Specific heat capacity - - 1.06 kJ / (kg × ^o C) Frost resistance - -F-100 Fire resistance limit - - EI-180 Weight of one panel 2440*610*100 - 87.5 kg

As can be seen from Table. 2, 3 the technical characteristics of the slabs meet the requirements of housing construction. At the same time, when comparing the weight of the plate obtained according to the claimed technical solution and the weight of the plate obtained according to the solution of the prototype, it turned out that, having the same dimensions, the weight of the prototype plate turned out to be higher by 51%.

Additional studies have shown that, on average, the reduction in the weight of external walls and partitions made of slabs, according to the proposed technical solution, ranges from 50% to 85% compared to walls and partitions made according to known technical solutions.

Table 3 Specifications Prototype Forming sand density, kg/m ³ 1090 Density of finished products, kg / m ³ 880 Dry thermal conductivity, W/(m⋅K) 0.189 Sorption moisture, wt.% 5.8 Water absorption, wt.% 12.3 Compressive strength, MPa 5.91 Bending strength, MPa 1.52 Weight of one panel 2440*610*100, kg 132.12

Claims (2)

A mixture for the manufacture of expanded polystyrene concrete slabs, including Portland cement, expanded polystyrene, a superplasticizer and water, characterized in that a polycarboxylate superplasticizer is used as a superplasticizer, and additionally the mixture includes ground granulated blast-furnace slag, microsilica, sand, redispersible polymer powder in the following ratio of components, wt. %: Portland cement 47.3-66.0 ground granulated blast-furnace slag 5.0-7.0 microsilica 5.0-7.0 sand 0.0-28.3 redispersible polymer powder 0.5-0.7 polystyrene foam 1.5-2.1 polycarboxylate superplasticizer 1.1-1.5 water 11.3-15.7