TR201617072A2 - INSULATED LIGHT MASS CONSTRUCTION BLOCKS AND DEVELOPMENTS IN THE PRODUCTION METHOD OF THIS PRODUCT - Google Patents

Abstract

Our invention; used in all buildings where insulation is required, block walling, precast panel production and assembly or on-site casting applications can be done very easily, long-lasting, does not require insulation, providing very good heat and sound insulation, no harmful substances in nature, extremely cost-effective, fire and freeze / melt resistance and low water absorption due to its high workability and self-settling, in addition to being cheap, as well as a significant reduction in building loads, resulting in cost reductions due to vertical and earthquake loads. is concerned with insulated lightweight masonry building blocks, which enable the evaluation of ash as an industrial waste and improve quality, especially in the manufacture of concrete, and improvements in the production method of this product. Subject to the invention; `Improvements in Insulated Lightweight Masonry Building Blocks and Production Method of This Product çimento, cement, EPS beads, ash, marble powder (aggregate), perlite (light aggregate), building chemicals (foam agent, sulfate and polymer based strength enhancer) and water.

Description

DESCRIPTION INSULATED LIGHT MASONRY BUILDING BLOCKS AND OF THIS PRODUCT IMPROVEMENTS IN PRODUCTION METHOD Our Invention; Block wall construction, precast panel used in all buildings where insulation is required. production and assembly or in-situ casting applications are extremely simple. Very good heat and sound insulation, long lasting, does not require isolation providing a high level of workability, which does not contain any waste materials harmful to nature. high and self-compacting, in addition to being cheap, the building decreases in vertical loads and earthquake loads, as it provides a serious reduction in loads fire resistance and freeze/thaw resistance, which also provides cost reductions due to ash, which is extremely high and has low water absorption, and is an industrial waste. insulated, which enables the evaluation of the relates to lightweight masonry building blocks and improvements in the manufacturing method for this product.

State of the Art: Concrete is widely used in all kinds of structural elements in civil engineering. is a material. Although concrete is a good carrier, its unit weight is large. Due to the fact that the dead load value in the structure reaches quite large dimensions. Especially in high-rise buildings where the ratio of dead load value to total load value is large. The function of unit weight is more important in structural elements with large spans such as buildings. is gaining importance. On the other hand, due to the large unit weight of normal concrete, Therefore, the thermal conductivity coefficient is also high.

By creating voids in the concrete in various ways or by normalizing the unit weight. unit weight of concrete using aggregates that are lower compared to aggregate can be lowered. The ones with low unit weight produced by any of these ways. Concrete is called lightweight concrete. Today, fly ash, silica fume, various Materials such as volcanic tuffs extracted from these regions are the most common materials in lightweight concrete production. are among those used. Studies have shown that lightweight concrete is used instead of normal concrete. Among the main reasons for using economy due to shrinkage, decrease in equipment and material requirements providing a second material for the increase of usable spaces, heat and sound insulation It does not need to be used, it has very high freeze-thaw and fire resistance. and also to be earthquake resistant.

The use of lightweight concrete instead of normal concrete, as well as the use of more the total amount of concrete to be used in the building by using high-class concretes will decrease and the buildings will become lighter, the effect of the earthquake on the buildings will be proportional to the weight of the building. As it is, the risk of collapse will also decrease. Light and delicate instead of heavy and bulky structures As the structures are built, the investment costs will also decrease. In addition, raising the concrete grade With this, the sections will narrow and the usage areas of the buildings will expand. Reinforced concrete There are many advantages of using lightweight concrete instead of traditional concrete in construction. These advantages are: 1. Due to the decrease in the total material weight in the unit volume, more low pressure is created, thus facilitating production and placement. 2. Due to the low unit weight of the elements produced with lightweight concrete, the structural loads are reduced, With this reduction, reinforcement economy is provided in the foundations and the elements under the effect of bending. 3. The basic dimensions are reduced due to the low unit mass. 4. Improvement of earthquake behavior is ensured.

. Heat insulation is high. 6. It is more durable than normal concrete in terms of fire. Especially in recent years, lightness, cheapness and less raw material in all production sectors. consumption comes to the fore. In addition to these features, high impact resistance, increased properties such as toughness, increased thermal stability, decreased electrical and thermal insulation. The use of polymer-based foam materials that can provide

Lower density compared to conventional materials and non-cellular polymers, material saving, superior strength/weight ratio, affordability, high heat and noise insulation, impact resistance, toughness, fatigue life, thermal stability, low dielectric constant, Polymeric foams with properties such as low thermal conductivity, furniture industry, transport, bedding, carpet underlays, packaging, textiles, toys, caps, sports applications are used in insulation applications.

Foam concrete, the stable foam obtained by the foam generator, homogeneously into the concrete. It is a porous lightweight concrete type produced by placing In the production process There is no chemical reaction other than cement hydration. plaster, handle, block mortar or can be used as reinforced concrete. The main ingredient of the foam that enters the mortar is foam. agent is a completely natural material and has no harmful aspects to human health.

Properties of foam concrete; It depends on the form, distribution and regularity of the gap formation. lsi The transmission coefficient (A) depends mainly on the density. Type of binder, curing conditions and has negligible effect on other factors. The most important feature is heat and sound. Since the air-gapped structure that provides insulation has closed cells, the same It also provides water insulation. Water absorption values are extremely low.

Foam concrete is a product with extremely high fire resistance. The life of foam concrete, same as normal concrete.

foam concrete; depending on its density; block, precast panel, existing frame in place cast wall, cast-in-situ wall forming a supporting carcass, handle, plaster, ornamental elements can be used in their manufacture.

Foam concretes: . In the production of heat-insulated lightweight concrete, . In the production of heat-insulated light bricks, briquettes, block bricks, wall panels, . In the production of heat and sound insulated handles, . Fiber reinforced concrete back, filling concrete for thermal insulation, . Cement and gypsum based light plate production, . In the production of heat-insulated light tiles and ceramics, . Basement floor in buildings, underground filling concrete for thermal insulation, 8. Light filling concrete to prevent collapses around the structure, 9. Porous filling concrete for underground water drainage, . Filling concrete under the road in order to prevent icing on the bridge and bridge road, 11. In the production of light concrete for tunnel and well filling purposes, 12. In the production of heat-insulated lightweight concrete with EPS styrofoam granules, 13. In the production of perlite plaster and light perlite concrete, 14. In steel construction systems, in the production of heat-insulated light floors and walls and . In prefabricated building production NOW-&GMA they are used.

Advantages of foam concrete: 0 It is a very long-lasting construction material. 0 It provides very good heat and sound insulation. It does not require isolation. 0 In the form of block masonry, precast panel production and assembly or in-situ casting Applications can be made very simply. . It does not generate any waste that is harmful to nature as a product or in the manufacturing process. o Its workability is extremely high. It has a self-adjusting feature. o In addition to being cheap as a product, it provides a serious reduction in building loads. indirect costs due to vertical loads and reductions in seismic loads. produces reductions. 0 Fire resistance is extremely high. Particularly fire resistant It is suitable for use in buildings.

. Freeze/thaw resistance is extremely high. 0 Water absorption is extremely low. o Since it is a completely cement-based material, all kinds of cement-based materials Its compatibility with the material is extremely high. (Walling mortar, plaster mortar, handle, reinforced concrete etc.) In developing societies, changing consumer demands as the socio-economic level rises, It forces manufacturers to produce new products that will meet the expectations of consumers. Especially in the last 20 years, the general population growth in the world and in Turkey, growth and In parallel with the increase in international communication and trade, consumers They demanded products for their needs. The 70's were the years when the need for energy and environmental awareness increased sharply. These artists In addition to the increase in the production of thermal power plants, the environmental impact of burned coal wastes It brought its problems with it. Fly ash spread all over the world in a very short time especially in manufacturing sectors such as construction sector, agriculture sector, chemical sector. Its use by giving results continues to increase today. These sectors The segment that provides the most economical conditions and provides very serious technical benefits, cement and concrete industry.

Evaluation of ash, which is an industrial waste, and improving quality especially in concrete production. It was noticed and started to be used in Turkey in the late 1990s.

The structure of the fly ash is spherical and spongy and the grain size is between I-200pm. changes. Generally, 85% of its chemical structure consists of SiOz, AlO3, Fe2O3, CaO and MgO.

In ash formation consisting of particles, the cenosphere shows dermosphere characteristics and has high It is decomposed due to heat. Volatile containing low calcium in its mineralogical structure ash reacts with calcium hydroxide in its humid environment and binds reveals its peculiarity. So they are pozzolanic. High calcium ashes are; chemical amorphous components in its structure, etc. Therefore, they have binding properties on their own.

Specific surfaces of fly ash vary between 1700-5000 cm2/g. a thermal as long as the raw material and manufacturing conditions of the power plant do not change, the ash of that power plant, the thickness does not change. Ashes held in electro-filters or separated from cement and suitable for use in concrete. Its density is about 800 kg/m3. in cement Its use is directly proportional to its fineness. Fly ash over 3500 blain direct mill can be given to the mixer from its outlet. Since there is no grinding and drying cost like shaving reduces cement production cost. Made with cement types prepared with fly ash decrease in the hydration heat of concrete, serious increases in its strength and workability It is possible. Cement factories manufacturing with fly ash additives increase capacity indirectly. they have increased.

If fly ash is used in concrete and its derivatives: > Strength increases a lot compared to portland cement and this increase lasts up to 400 days. > Since it fills the space, it prevents reinforcement corrosion. > Prevents concrete cracks as it reduces hydration temperature. > Provides serious impermeability. > It reduces the water need of concrete at certain rates. > Provides little isolation. > The processing rate of concrete increases a lot. > Prevents shrinkage in concrete. > Prevents vomiting and segregation in concrete.

Transporting, stocking, and mixing into concrete are just like cement. A certain amount of cement It can be used instead of fine aggregate as well as in place of fine aggregate. Qualification of ash and aggregate and according to their quantity, the best result as a result of laboratory studies; both cement, It has been determined that it is taken when used instead of fine aggregate.

Also fly ash: -Brick production -In aerated concrete production -Injection concrete -Soil stabilization and Its use as a filling material is increasing day by day.

Fly ash, which is used at maximum levels in the world; Unfortunately in Turkey well below the average figures.

Both the value of an industrial waste and its contribution to the economy, and the production of cement cost reduction by saving energy, as well as saving human life from end uses. its positive contributions to ready mixed concrete that directly affects These are technical issues that cannot be ignored in our country, which is experiencing difficulties.

Perlite is a naturally occurring silica-based volcanic rock. In certain ranges of these rocks Crushed perlite aggregate is obtained. Expanded perlite aggregate, raw perlite After being sized by passing through sieves with different spacings, it is flamed at 900-1100°C. As a result of loss of body water in It is a white or gray material.

Light perlite aggregate; by mixing it with a binder such as cement, gypsum or lime. The produced concrete and/or plaster mortars are light, non-combustible, rot-proof, water-proof, heat-resistant. Building materials with low permeability and high sound absorption ability are obtained. can be done.

Increasing the effective usage area of perlite as concrete aggregate in the construction sector, Due to its insulation feature and lightness, it has a positive effect on the country's economy and global warming. is thought to contribute. Thanks to the properties of perlite, the concretes produced Energy efficiency with better thermal performance than normal concrete is provided. The microscopic air sacs and cavities in the perlite make this aggregate light and makes it difficult to work.

Perlite, with a special texture, containing a certain amount of water in its internal structure, acid composition, essentially volcanic it is glass. It is not made of fiber. nitrate sulfate, phosphorus, heavy metal, radioactive element and organic Does not contain substance. Therefore, it is very pure chemically.

Lightweight perlite aggregate has been increasingly used in our country recently. has been launched. Perlite is a binder material such as cement, gypsum or lime combined with water. The mixtures obtained by adding In acoustic walls and ceilings that require absorption, non-overload-bearing walls and ceilings in slabs, in the manufacture of lightweight construction infill and in prefabricated tile and briquette making is widely used. In addition, perlite, in powder form without binder materials, two By filling in between the wall, the heat transmittance sensitivity is obtained in the most perfect way. possible to take advantage of.

Our Invention; EPS beads (expanded polystyrene), cement, ash, marble dust (aggregate), perlite (light aggregate), construction chemicals (foaming agent, sulfate and polymer based They are self-insulating lightweight masonry building blocks containing strength increaser) and water. Production technique, material structure and technological features It is called both a lightweight concrete and a foam concrete in terms of possible.

Used in our invention; Expanded Polystyrene Rigid Foam (EPS-Expanded Polystyrene) Foam), obtained from petroleum by polymerization of styrene monomer, closed foamy It is a porous typically white thermoplastic material. EPS, Polystyrene beads, It is obtained by inflating the raw material with pentane setting agent and steam.

If EPS material; It is obtained by the fusion of steam and pentane. an organic ingredient Pentane, which is a chemical substance, allows the formation of many small pores in the particles. Then, it is replaced by air in a very short time during and after production. agiga The emitted pentane gas is converted to 002 and water vapor-HZO, which is already in the atmosphere.

With the release of pentane, a large number of (density) contained in the material 3-6 billion (depending on 1 m3 of EPS) stagnant in cells with small closed pores air is trapped. EPS is produced in desired densities according to the usage area.

With the use of EPS beads and EPS beads provided in our invention advantages: - Shock absorbing ability and compression resistance, excellent protection it earns.

- Even in humid conditions, there is no decrease in strength.

- Resistant to moisture, thus meeting the highest hygiene requirements.

- EPS is also odorless and non-toxic.

- 98% of EPS is air, these conditions make the material very light.

- Environmentally harmless Pentane gas and water vapor are used in the production of EPS.

- Heat insulation stability is constant in EPS.

- B1 class (non-flammable) raw material is used.

- EPS can be produced in desired density.

- EPS is an everlasting material.

- EPS vapor diffusion resistance is low.

- It is one of the best heat insulation materials. - It is environmentally friendly. It does not harm nature and human health.

- In the buildings where EPS is applied, it immediately starts heat insulation.

- Thermal insulation values do not change in the direction of increasing or decreasing over time.

- EPS works in harmony with the construction materials in the buildings where it is applied.

- The life of EPS is equivalent to the structure.

- The thermal conductivity of EPS depends on the density. As the density increases, the thermal conductivity decreases.

- EPS is very resistant to pressure. As the density increases, the compressive strength increases. - It is very light.

- It has a very high resistance against pressure, impacts and falling.

- Water, water vapor, humidity and dust proof.

- It is not corrosive. Protects metal products from corrosion and rust.

- It is an advanced technology product and can be produced in large numbers in a short time.

- Resistant to many chemicals. - It is environmentally friendly and does not harm nature. It is reversible.

- It does not contain CFCs (chlorofluorocarbons), which are harmful to the ozone layer.

- Since the thermal conductivity coefficient is very low, they hardly conduct heat and cold.

Existing building materials are heavy products and bring extra loads to buildings.

Both masonry, sheathing time, workmanship, etc. wall finishing for reasons process can be completed in a very long time. 1. In the products on the market; -Wall knitting -Plaster work -Sheathing workmanship and -There are four different types of work, such as plastering again. 2. These products on the market especially; In the inner and northern regions of Turkey, in big cities does not provide the required thermal insulation values. Extra sheathing material cost and it wastes time. 3. The necessity of renewing the sheathing materials used over time, therefore, incurs additional costs. 4. Due to the heavy weight of other products, more iron and concrete in static calculations use is required.

. Moisture and mold formation inside the walls with the use of sheathing materials brings the result. 6. Since the existing products are heavy, their workmanship is difficult. 7. Existing products are broken when they fall to the ground and they are difficult to process. fire rates are high. 8. Since it can only work with additional wall manufacturing processes, on-site manufacturing times and costs are rising.

Most of the insulation products sold on the market; air-filled fragile glass and essentially produced to be used as cheap filler in plastic production, ceramic air consists of bubbles. These are the so-called insulating additives, the insulating material it does not provide any benefit to improve its properties.

Existing building materials are heavy products and bring extra loads to buildings.

Both masonry, sheathing time, workmanship, etc. wall finishing for reasons process can be completed in a very long time.

With our invention, all the above-mentioned problems are eliminated.

Features and advantages of our invention; With the perlite (light aggregate) used, 50% more lightness is achieved and the building It is ensured that no extra load is placed on its weight. Since it is much lighter, it brings advantages in static calculations of buildings. More Lighter buildings are built with less reinforcement and concrete. This is a cost-saving Physical strength and chemical resistance are greatly increased.

As it fills the space with the ash used, reinforcement corrosion is prevented.

Concrete cracks are prevented as the hydration temperature decreases.

- A serious level of impermeability is provided.

- Water need of concrete decreases at certain rates.

- The processing rate of concrete increases a lot.

- Shrinkage in concrete is prevented.

- Vomiting and segregation in concrete is prevented.

- It is insulated.

- Its lightness feature increases further, it can be processed quickly and easily, in construction and application time is saved.

- Both masonry and thermal insulation are provided with a single workmanship. Like this, site time is shortened and labor costs are also reduced.

- It holds plaster and plaster easily thanks to the components it contains.

- It has flame retardant feature and prevents the spread of fire.

- It increases energy efficiency and provides financial savings. your isolation There is no need for extra power and cost for its protection, it is permanent and generally maintenance free. not required.

- Rejection of ultraviolet rays from the sun and at the same time indoor By preventing the accumulation of heat, it ensures the protection of the heat inside.

- Corrosion resistance and comfort in the places used with the EPS beads used level and reduces energy costs. To the atmosphere to which it is applied They provide thermal insulation on open surfaces and keep insects such as termites away.

- It is at peace with nature and human health as it does not contain any toxic substances. heat, sound, It has water insulation and rust prevention features.

- Its physical and chemical resistance is extremely high. - Its covering power is high and its resistance to climatic conditions is extremely good.

Detailed Description: The subject of the invention in question; “Insulated Light Masonry Building Blocks and Belonging to This Product “Improvements in Production Method”; Cement, EPS beads, ash, marble powder (aggregate), perlite (light aggregate), construction chemicals (foaming agent, sulfate and polymer based strength increaser) and water.

The subject of the invention in question; “Insulated Light Masonry Building Blocks and Belonging to This Product “Improvements in Production Method”; Cement; providing heat insulation and mixing EPS beads, which are added to lighten the mixture; liquid in lightweight concrete and mortar production foaming agent used as a foaming additive; concrete with its high water-reducing property. sulphate, which provides fluidization; processes such as finishing in concrete, removing formwork shorter time, early high strength and cold polymer-based strength increaser that allows concrete to be poured in weather; a blank marble powder (aggregate), which provides concrete mix; substance and By providing 50% lightness to the mixtures, it does not add extra load to the building weight and providing more durability and increasing physical strength and chemical resistance, perlite (light aggregate); which prevents corrosion by filling gaps, increases strength and homogeneous, providing impermeability, ash and all the materials used are identical with each other. It consists of water, which ensures mixing.

Our invention is in 1 m3; 0 240 kg Cement o 50 kg Ash 0 7.5 kg EPS beads o 30 kg Marble powder (Aggregate) o 10 kg Perlite (Light Aggregate) o 80 liters of water 0 0.30-O.60 kg Foaming agent 1.25-1.80 kg Sulphate 0 100-130 kg Polymer based strength increaser consists of

There are three types of construction chemicals in our invention. These: - Foaming agent - Sulphate and - It is a polymer based strength increaser.

In our invention; EPS's are converted from granules to beads. EPSs It is used as a bead in the mixture that makes up our invention.

Production phase of our invention; o EPS's are turned into beads from granules. o EPS beads, cement, ash, construction chemicals (foaming agent, sulfate and polymer based strength increaser), marble powder (aggregate), perlite (light aggregate) and water are combined and mixed in a mixer, o The mixture prepared after the mixture is finished; width: 60 cm (+/-) 1; length : 240 cm (+/-) 1; height : 60 cm (+/-) 1 is poured into mold trolleys, o Mixture poured into die carts, 8 hours of rest and withdrawal left to dry, (This process is done without touching) 0 After the mixture has dried, the carts are transferred to the lines, 0 When the mixture in the carts transferred to the lines reaches the cutting hardness (Mixes that have reached cutting hardness are called blocks) o The blocks that have reached the cutting hardness are opened automatically, o The blocks are taken to the cutting line where they are used in automatic cutting machines. width: 298mm; length: 598mm; height: 98mm width: 298mm; length: 598mm; height: 148mm width: 298mm; length: 598mm; height: 173mm width: 298mm; length: 598mm; height: 198mm are cut to size and sized, o After the sizing process is finished, the packages are arranged and placed on the packaging line. The product is packed and lined up in the stock area and o It is offered to the market after the maturation phase here.

Claims (1)

REQUESTS . The subject of the patent in question; It is “Insulated Light Masonry Building Blocks” and its feature is; Cement; EPS beads, which provide heat insulation and lighten the mixture by being added to the mixture; foaming agent used as a liquid foam additive in the production of lightweight concrete and mortar; sulphate, which provides fluidization of concrete with its high water-reducing feature; polymer-based strength enhancer, which enables concrete finishing and mold removal processes to be carried out in a shorter time, to obtain early high strength and to pour concrete in cold weather; marble powder (aggregate), which provides a void-free concrete mix; Perlite (light aggregate), which provides 50% lightness to the materials and mixtures it is mixed with, does not add extra load to the weight of the building and provides 7 times more durability and increases physical strength and chemical resistance; It is characterized by the fact that it contains water, which prevents corrosion by filling spaces, increases strength and provides impermeability, ensures homogeneous mixing of ash and all materials used with each other. . It is “Insulated Light Masonry Building Blocks” in accordance with Claim 1 and its feature is; as a construction chemical; It is characterized by containing foaming agent, sulfate and polymer based strength increaser. . It is “Insulated Light Masonry Building Blocks” in accordance with Claim 1 and its feature is; in 1 m3; 240 kg Cement, 50 kg Ash, , 10 kg It is characterized by containing 1.00-1.30 kg of polymer-based strength increaser. . It is “Improvements in Production Method of Insulated Light Masonry Building Blocks” in accordance with Claim 1 and its feature is; production stage; Making EPS from granule into beads, EPS beads, cement, ash, construction chemicals (foaming agent, sulfate and polymer based strength increaser), marble powder (aggregate), perlite (light aggregate) and water in a mixer at the specified rates. combining and mixing, The mixture prepared after the mixture is finished; width: 60 cm (+/-) 1; length : 240 cm (+/-) 1; Height : Pouring the mixture poured into the mold trolleys with 60 cm (+/-) 1, Letting the mixture poured into the molding trolleys to dry after 8 hours of rest and shrinkage untouched, Transferring the molding trolleys to the lines after the mixture has dried, , waiting for them to reach the cutting hardness, (Mixes that have reached the cut hardness are called blocks) Automatic opening of the blocks that have reached the cutting hardness, Taking the blocks to the cutting line and here in automatic cutting machines, the width: 298 mm; length: 598mm; height: 98 mm width: 298 mm; length: 598mm; height: 148 mm width: 298 mm; length: 598mm; height: 173 mm width: 298 mm; length: 598mm; height: Cutting and sizing in 198 mm dimensions, arranging them in packages after the sizing process is finished, packing them on the packaging line and arranging them in the product stock area and presenting them to the market after the maturation phase. It is characterized by the fact that it consists of process steps.