Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
  • C04B28/04—Portland cements
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B7/00—Hydraulic cements
  • C04B7/02—Portland cement
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
  • E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/20—Resistance against chemical, physical or biological attack
  • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
  • C04B2201/30—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values
  • C04B2201/32—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values for the thermal conductivity, e.g. K-factors
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/92—Protection against other undesired influences or dangers
  • E04B1/94—Protection against other undesired influences or dangers against fire
  • E04B1/941—Building elements specially adapted therefor
  • E04B1/942—Building elements specially adapted therefor slab-shaped
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
  • Y10T428/249932—Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]

Definitions

• This invention relates to a new type of incombustible cement wood, its use allowing an increased safety of the buildings against fire action, simultaneously providing the remaining properties of high durability, mechanical strength, acoustic behaviour and aesthetical interest, which are usual for this kind of material.
• the panels or coatings made from solid wood or wood derivatives have a high bending strength, such as in the case of plywood, medium density fiberboards (MDF) or particle boards (OSB), they also have a low performance in terms of water resistance, dimensional stability, in addition to high susceptibility to attacks from fungi, insects and microorganisms, as well as low performance in what concerns its reaction to fire (in most cases with a classification equivalent to euroclass D).
• MDF medium density fiberboards
• OSB particle boards
• the patent U.S. Pat. No. 5,342,566 is in line with the previous ones, however it comprises the use of light-weight fillers, such as perlite, combined with gypsum and cellulose fibers, for the production of multilayer panels.
• the possibility to use fibers of different origins is mentioned, such as glass or another mineral, and/or polypropylene in percentages ranging from 10 to 20%. All of these panels are considered incombustible according to ASTM E 136, but their formula does not contain cement and that is the reason why they have a limited scope of application, particularly in what concerns demands of a structural nature and exposure to outer environment.
• the main advantage of the invention is based in the fact that it is an incombustible panel, without generating incandescent drops and with a reduced smoke production, thus helping to minimize the risk of fire deflagration and propagation in the buildings and therefore contributing to an increased safety of people and property in case of fire. Simultaneously, it shows a good performance in terms of thermal and acoustic behaviour, resistance to impact, tensile and bending strength, resistance to humidity, as well as stability from the dimensional point of view and resistance to fungi, insects and microorganisms, in addition to being economically competitive and very easily applied. Considering all of these characteristics, it can be used in a wide variety of domains, inclusively with structural and architectural functions in inner and outer spaces.
• composition is aimed at minimizing the incorporation of organic matter in the form of wood chips in order to not compromise the panel's mechanical strengths (in special, the bending strength), and the combination of the calcium sulphate in the form of semi-hydrate with the cement, according to the carefully determined proportions so as to control eventual expansive reactions which might be generated, provides a very good behaviour as regards fire, causing the material to be incombustible.
• This new benefit significantly increases the scope of application of the product and improves the behaviour of buildings under the action of fire.
• the object of this invention is an incombustible composite panel of high performance, made of Portland cement, gypsum and wood particles, comprising in weight percentage of the components with reference to the total weight of the composition:
• the resinous wood which is commonly used to obtain the component 2) is pinewood.
• the wood particles used therein are in the form of chips.
• the thickness of the said chips ranges from 0.25 to 0.32 mm.
• 50 to 70% of the said chips are ⁇ 1 mm long and 26 to 40%, preferably about 1 ⁇ 3, have a length of 1 to 4 mm.
• the percentage of the component 3) is of about 11%.
• the surface accelerator being used as the component 4) is a sodium silicate solution with a density between 1.10 and 1.15 g/cm 3 , wherein the sodium silicate has a SiO 2 /Na 2 O ratio between 3.19 and 3.53.
• the aluminium sulphate which is used as the component 5 normally has a density ranging from 1.05 to 1.10 g/cm 3 .
• the calcium carbonate being used as the component 6) is generally limestone filler, which is the result of the fine grinding of lime materials.
• the pigments being commonly used as the component 7) are metal oxide pigments.
• the composite panel according to the invention pertains to Class A in compliance with ASTM E 136 and to Class A2 in compliance with EN 13501-1 and DIN 4102, having a good performance in terms of mechanical strengths, generally with a tensile strength under bending >9 N/mm 2 and a tensile strength perpendicular to the plane >0.5 N/mm 2 , elasticity modulus >4000 N/mm 2 and thermal conductivity ⁇ 0.23 W/m 2 .K.
• This formula aims both at minimizing the incorporation of wood chips and introducing a mixture of binders with the incorporation of Portland cement and semi-hydrated calcium sulphate, in order to ensure the characteristic minimum bending strength above 9 N/mm 2 .
• the cements used are grey or white Portland cements, depending on the desired colour of the panel and according to the EN 197-1, which present fast-developing strengths (designation “R” of the relevant standard).
• gypsum in the form of semi-hydrated calcium sulphate in controlled percentages, will not only provide the mixture with an acceleration of the setting process, but also an improvement of the panel's thermal behaviour and fire resistance.
• the wood chips used which can be from pinewood or other resinous wood, are then broken and thinned to the following dimensions:
• the water to be used shall be clean (colourless and odourless), preferably drinking water, and free from oils or other impurities which might contaminate the colour of the concrete, so as to comply with the provisions of the EN 1008.
• the pigments suitable to the manufacture of the said mixture shall be inorganic and have the desired colour.
• the manufacturing of the board is in accordance with the industrial process of the previously mentioned Viroc panel, in an appropriate installation. It comprises a wood treatment step, with debarking, cutting and defibrillation to the previously referred dimensions, followed by mixing of the constituents for at least 90s in an industrial mixer, followed by the conformation of the board using a conformation equipment, followed by pressing for the purposes of dimensional stabilization. Subsequently, it is cured in a hardening chamber, air-matured and finally dried in a drying tunnel. After this, the plate is cut, rectified and packed.
• the logs of wood are reduced into chips.
• the latter are thinned and divided into a group of larger chips with 1 to 4 mm and another group of thinner chips with a thickness lower than 1 mm.
• the chips are introduced in the mixer wherein after 30 seconds half of the water required for the process is also introduced (this varying according to the equipment used) and after another period of 30 seconds, the remaining portion of water is added. Again after 30 seconds, the aluminium sulphate is introduced and then, after 60 seconds, the sodium silicate solution.
• the cement and the gypsum are premixed for 60 s, and then added to the remaining constituents in the main mixer.
• the mixture's conformation step is started, in which the said mixture is distributed with an even thickness over steel plates, thus forming a mattress.
• a stack of alternate plates and mattresses is formed with a number of stages according to the thickness of the boards to be manufactured.
• the stack is pressed and introduced in a hardening chamber, in which, under the effect of pressure, temperature and humidity and length of stay, it will gain the required strength in order to be handled.
• This set of boards is decompressed and the boards are separated from the plates.
• the panels are subjected to a precut operation and subsequently they are stacked and left to mature in a covered park. After maturation, the boards are introduced in the drying tunnel in order to remove the excess moisture.
• the boards are cut to the desired size and treated in the surface.
• this type of panels in façades offers several benefits due to the fact that it is a building material which can be used on outer spaces as well, with a good behaviour while enduring sun exposure, wet and dry cycles of rainwater, freeze and thaw cycles, and also due to its acoustic and mechanical strengths, in addition to its easy application and workability, which enables it to be applied as is, or a finishing can be adopted such as painting or coating with ceramic materials.
• Another possible application is for the purpose of building structural or dividing walls, both in inner and outer spaces.

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Architecture (AREA)
• Inorganic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Civil Engineering (AREA)
• Building Environments (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Environmental & Geological Engineering (AREA)
• Dry Formation Of Fiberboard And The Like (AREA)
• Panels For Use In Building Construction (AREA)

Priority Applications (1)

Applications Claiming Priority (2)

Related Child Applications (1)

Publications (1)

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Family Applications (2)

Family Applications After (1)

Country Status (3)

Cited By (4)

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• 2011
  • 2011-11-16 PT PT106007A patent/PT106007A/pt not_active IP Right Cessation
• 2012
  • 2012-11-16 US US13/678,859 patent/US20130139731A1/en not_active Abandoned
  • 2012-11-16 BR BRBR102012029312-9A patent/BR102012029312A2/pt not_active IP Right Cessation
• 2013
  • 2013-10-25 US US14/063,814 patent/US8852338B2/en not_active Expired - Fee Related

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