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

Definitions

• This invention relates to a method of producing stable, non-segregating lightweight aggregate concrete of extremely low density and monolithic structure, which is attained by introducing an especially stable air-void system consisting of small as well as large spherical air bubbles and by partly replacing middle sized aggregate particles, by particles of extremly low density.
• the walls of the air bubbles have been strengthened by flocculating the cement particles.
• a well-designed monolithic lightweight aggregate concrete has approximately the following composition: cement 10 percent by volume water 20 " " " air pores 10 " " " fine aggregate 10 " " “ coarse aggregate 50 " " " "
• Air bubbles are created during the mixing procedure.
• Sand particles with diameter of 0,2-0,6 mm have in this respect appeared to be of great importance for the formation of air bubbles.
• the mechanism of the formation is based on co-operation between stirring air-entraining agent, cement particles, water- and sand-particles. These particles will give roughness at the free interfaces between water and air. When two opposite surfaces join an air bubble will be enclosed.
• Sandparticles are to be found afterwards near to the air voids and they give geometrical and mechanical protection against collapse.
• the particle density of the different sizes has great importance for the stability of the fresh concrete. Hereby it is desirable that the particle density should decreases with decreasing diameter of the particles.
• the relation between the particle density, the density of the surrounding matrix, cement mortar or paste, diameter of the particle and the buoyancy speed rate of the particle is expressed by Stokes formula.
• the particle density increases with decreasing particle size for porous aggregates. This is particularly pronounced for a synthetic mineral aggregate, which has been sintered to particles in rotary kilns, e.g. expanded clay aggregate. Most lightweight aggregates will suffer from an unfavourable distribution of particle density.
• the segregation has been prevented by strengthening the thixotropy of the cement paste and by thickening of the border region close to air bubbles.
• Thixotropy manufests itself as a difference between the viscosity of the cement paste at rest and during vibration.
• the concrete is sufficiently mobile and formable only during compaction.
• the air voids are created during mixing by lowering the surface tension of the water or by adsorbing with hydrophobic - hydrophobic particles at the air-water interfaces.
• the stability depends on strength, deformability and impermeability of the bubble walls, which surround the air voids.
• Air voids together with their walls increase the mobility of the concrete at the same time as they hinder the single aggregate particles from moving freely.
• the risk of segregation is especially great when the density of the aggregate particles differs considerably from the density of the surrounding continuous matrix as the viscosity of this matrix is low, for example during vibration and when the volume of the aggregate is small.
• the classical theory referring to the stability of concrete is based on the influence of the gravitation at forces on the individual descrete components and on the variability of the properties with time under the influence of superimposed forces. Bird. Stewart and Lightfoot have proposed a mathematical relationship applicable to moving particles in different media.
• Stokes' formula may be considered as a special case of this relationship.
• the velocity of the particles according to Stokes' formula may be calculated by using following expression:
• d is the diameter of the particles, is the difference between the density of the particles and the continuous matrix and is the viscosity of the matrix.
• Stokes ' fo rmu la is usua l ly used when discuss ing the s tab ility o f fresh concre te .
• the cement pas te should be cons ide red as a mat r ix , and fo r the aggrega te part icles a l l o f the ma t r ix inc luding part ic les o f smal ler s ize than the smallest aggregate particle.
• Pure cement paste has the lowest viscosity and the more air voids and particles added to the paste, the more the viscosity will increase.
• the final result is that when the diameter of the particle increases the difference between the density of the particles and the density of the matrix should be reduced and at the same time the viscosity increased in order to keep the velocity constant. This will be fulfilled for lightweight aggregate concrete if the particle density decreases with increasing particle size. The movement of the largest particle should be brought to a minimum. The attraction forces
• a conventional solution amounts to adding some admixture known as an air entraining agent which acts at the molecular level by adsorption at the interfaces water-air, by partly hydrophobising cement particles or by precipitating and creating partly hydrophobic flocks. In all cases and adsorption occurs at the interfaces water-air.
• the invention utilizes a synthetic hydrophobic polymer particle covered with a calcium-stable anionic surfactant. The particle has a diameter of about 1/10 of the average size of the cement particles, i.e. 5 ⁇ m .
• the particles By adjusting the hydrophility and hydrophobity of the particles, they are capable of being absorbed at the interfaces between air and water and thus making a contribution to the creation and stabilization of the air voids.
• the concentration of the polymer microparticles at the surface of the air bubbles has been studied by the SEM-technique.
• the mobility of the concrete mass with its aggregate and air voids is located at shear surfaces between the aggregate particles and the air voids.
• something like a strong shell is formed around the air bubbles which counteracts the recombination of the air voids and retards the air diffusion.
• the procedure of building strong walls at the air bubbles during stirring or kneading and other treatment at the fresh state by activation of multifunctional polymer particles on whose surfaces different systems of surfactants have been adsorbed, is described below.
• Strengthening of the air void system is based on utilization of different polymer particles, above all stabilized by different surfactants. It is preferable that the polymer particles should be stable among themselves and that they can be mixed and stored in the state of one single dispersion with the concentration of 10 to 50%.
• the first type consists of small microparticles with diameter of 0,1-1,0 ⁇ m, stabilized by an anionic or anionic - nonionic surfactant, mostly stable to calcium ions (divalent cations) and high pH-values (> 12).
• the polymer particles may consist of homopolymers or copolymers with hydrophobic as well as hydrophilic groups, preferably hydrophobic. Their distribution should be adjusted to the surfactant system among other things.
• the actual substance of the particles may be film-forming or not on the walls of the air pores or capillary pores at normal temperatures.
• semipermeable polymer membranes are formed. By their hydrophobic properties and limited permeability they positively influence the durability of the concrete.
• the second type included consists of polymer particles, natural or synthetsized, with diameters of 1-5 ⁇ m, corresponding to the average diameter of cement particles, stabilized with one or more anionic non calcium-stable surfactant or a surfactant unstable at high pH-values.
• Some surface-active agents, surfactants, can depending on their structure, be absorbed at surfaces.
• the hydrophobic parts of the surfactants are adsorbed at surfaces with hydropobic character, such as hydrophobic particles.
• Addition of cement and aggregate particles to the polymer dispersion means that fresh surfaces are added and sufactants may be transfered from polymer surfaces via waterphase in the concrete to the fresh surfaces even if these are predominantly of hydrophilic character.
• sufactants By such a redistribution of the surfactants at the fresh surfaces the hydrophobic surface of the polymer particles will increase and thus the ability itself to be absorbed at the interfaces into the surfaces of air bubbles.
• the stripping effect can be strengthened by adding fresh hydrophobic surfaces to the concrete, such as polymer particles whose surfaces have not previously been covered with surfactants.
• the polymer particles may have the same sizes as aggregate particles or smaller. Tranferrance and adsorption increase in strength with the increased hydrophobicity.
• the quantity of redistributed surfactant is proportional to the hydrophobic area.
• the described phenomenon is linked to the calcium-stable surfactants.
• the other type of polymer particles with destabilized surfactant will rapidly be changed or converted on contact with the mixing water so that the polymer microparticles are no longer dispersable. Owing to this surfaces will loose their charge or be stripped by precipitation of the surfactant.
• the particles may be flocculated or in one way or an other added to cement or aggregate particles. The thixotropy of the cement paste will be strengthened.
• the air voids can be regarded as a part of an empty particle with walls of cement paste stabilized by polymer partides.
• the state described has been verified by microscopy, whereby a comparison has been made between different types of air entraining agents. An obvious difference is observed between the structure of the walls when using conventional air entraining agens and using only polymer particles with an air-void stabilizing effect, showing more or less far advanced recombination.
• the density of the so-called air-void particles or the apparent density may be calculated from the expression: where t is the thickness of the wall and D is the diameter of the air void. For a thickness of 1/10 of the diameter the apparent density of the air pore will be in the region of 600-800 kg/m 3 , i.e of the same density as normal lightweight aggregate.
• An essential part of the invention is vaiously acting polymer microparticles with the purpose of stabilizing air pores and concrete masses of lightweight aggregate particle.
• the microparticles have two sizes and they have been stabilizied by different surfactant systems.
• the small particles should be urn mainly spherical, have a diameter of 0,1-1,0 ⁇ m , be chemically inert in comparison to the remaining components of the mortar and should be distinguished by their surface which is hydrophobic. On this hydrophobic surface an anionic or weakly anionic (anionic - nonionic) surfactant has been adsorbed corresponding to 0,1-5,0 percent by weight calculated for the surface of the particle.
• the surfactant should be stable or partly stable with respect to calcium ions and high pH-values.
• As a particle shaped product a homopolymer or a copolymer of styren and/or one or more esters of acrylic or methacrylic acid should be used, with the general formula
• Variants may be particles whose hydrophobic part consists of styren or acrylates.
• the particles may consist of a copolymer of the type acryl-vinylidenchloride or a pure vinyllidenchloride on the surface of which 0,1-3,0 percent by weight of an anionic surfactant or anionic-nonionic surfactant combination has been adsorbed.
• a third variant of this particle material may consist of particles of a copolymer of styren-butadien on the surface of which 0,1-5,0 percent by weight on anionic or anionic-nonionic surfactant have been adsorbed.
• the particle material may consist of polyethylen on the surface of which anionic or nonionic surfactant combination has been adsorbed by the amount 0,1-5,0 percent by weight.
• the rest of the particles consists of the larger type with particle diameter of 0,5-10 ⁇ m, preferably 1-5 ⁇ m of a synthetized type or nonsynthetized hydrophobic natural product such as asphalt on the surface of which an anionic calciumdestabilizeable surfactant has been adsorbed.
• a synthetized type or nonsynthetized hydrophobic natural product such as asphalt on the surface of which an anionic calciumdestabilizeable surfactant has been adsorbed.
• surfactants for example soaps of different types may be used.
• the particle material of synthesized types may be most simply produced by emulsion polymerisation according to an earlier known technique, but the hydrophobic-hydrophilic balance, which is reflected by the existing euilibrium of the particles between the hydrophobic particles and the on these partides adsorbed, quantity of anionic or anionic-nonionic surfactant combination of calciumstable character, is by no means the one which is reached by an wholy conventional emulsion polymerisation.
• the balance between the hydrophobic, synthetic, smaller particles and on their surfaces adsorbed quantities of anionic or anionic-nonionic surfactant combination indicate in a relativly general way as acurately as possible the quantity of surfactant which may be stably adsorbed on the surface of the particles.
• the material of the larger particle size should be covered with such a surfactant that the destabilization and precipitation can take place so rapidly and completely that these particles do not acquireadsorbing properties for the interfaces water-air. This is possible by using surfactants belonging to the soap types.
• the particles are a part of the mixture of cement-grains and water with an even distribution and are especially concentrated at the walls of the air voids.
• the ratio between the small and large ones appears to be about 5-30%, preferably 15-25%.
• a too large amount of the calcium sensitive particles may increase the required water to cement ratio and thereby impair the properties of the hardened concrete. Further a too large proportion of big polymer particles may cause inhomogenity of the cement paste.
• the surfactants which are used for stabilizing the smaller polymer microparticles, are even active in wetting the surface of the aggregate. Principally this is valid for surfactants which are calcium stable.
• hydrophobic aggregate may be mentioned those which consist of polystyren, polyethylen, polyvinylchloride etc. In general the larger the hydrophobity of the surfaces the stronger they will adsorb the surfactant. Wetting is essential for the combination with water in the cement paste.
• the calcium sensitive surfactant which belongs to the stabilization of the large polymerparticles is to be found even free and unadsorbed. By binding calcium ions the surfactants have lost their surfactant effect but may contribute as a hydrophobic matter in the cement paste.
• a known method is to add soaps in order to hydrophobize concrete. It is practical to quantity the total amount of added polymer microparticles according to the amount of cement. The described effects are reached at an addition of 0,2-3,0 percent by weight for the cement of all the included and defined microparticles, preferably 0,4-1, 2%. Then it is possible to get an air void volume in the range of 0,06-0,18 m 3 /m 3 of the total volume of concrete, mostly in the range of 0,08-0,12 m 3 /m 3 . Here it is assumed that the amount of cement is totally of
• Lightweight aggregate with particle size of 4-8 mm and particle density of 700 kg/m 3 is mixed with particles of expanded polystyren with particle size of 2-4 mm and particle density of 30 kg/m 3 with the volume ratio of 1:1 in a container with transparent walls.
• the container ist placed on a vibration table, at a frequency of 50 Hz and the course of segregation during vibration is observed. After about 30 seconds the larger part of the lightweight polystyren particles will be concentrated at the bottom of the container.
• Air entraining agent 0,05% by weight of the amount of cement (51 air by volume).
• the concrete is poured into a mould, with a height of at least 50 cm. After one day the element is removed from the form and is cut vertically. It is now possible to observe a distinct segregation. The more lightweight polystyren particles have been displaced towards the bottom of the element by dynamic segregation. 4. Concrete with the composition according to paragraph 3, where the conventional air entraining agent has been replaced by the polymerdispersion described in the Swedisch patents 7614519-2, 7614518-8 and 8100489-7. The concrete will now contain air voids with a total volume of about 10%. During vibration the air voids will counteract the segregation of the aggregate - because the air voids have a tendency not to leave the cement paste but to be pushed towards the vibration source.
• the added, exceptionally lightweight aggregate particles are consist mainly of expanded polystyren with particle diameter of 0,5-4 mm.
• the added polymer microparticles were 0,5-3% of the cement weight, particularly 0,5-1,0%.
• the volume of added expanded polymer particles was 5-55% of the volume of the aggregate.
• Fresh concrete When preparing the concrete the expanded polystyren particles may be added after the addition of microparticles has partly reached its intended effect on the other components. Furthermore air-voids are also obtained in connection with wetting of the polymer surface of the hydrophobic aggregate.
• the interval of the concrete consistency in the density range of 700-1.200 kg/m 3 the flow table test value is 30-40 cm.
• the corresponding value for 3L-concrete is 36-42 cm.
• the cohessiveness and homogenity may be estimated by the flow table test in the same way as for normal concrete or 3L-concrete. Compaction of the concrete requires somewhat reduced and more distributed compaction energy. During compaction by vibration negligible segregation of both the lightweight and the heavy aggregate particle or of the cement paste is obtained.
• the water content could be reduced by 251 referred to the total volume of the air voids and expanded polystyren particles without changing the consistency.
• the particles should have spherical shape, not be water absorbing, have extremly low particle density and great deformability.
• One of the materials which fullfills these demands is e.xpanded polystyren particles of size from 0,5 mm up to slightly more than 8 mm.
• the particles act by affording good mobility to the concrete, of ballbearing effect.
• the mixing time could be kept short and the air entrainment facilitated.
• the strength of the hardened concrete follows the relationship which is to be found in the Olav Berge's Ph.d. thesis "Reinforced lightweight aggregate concrete structures” Cin Swedish) and may be assumed to be a function of the equivalent strength of the mortar and aggregate and their volumes.
• the tests, which have been carried out, indicate that the average strength is 10-151 higher than the expected values. This may be explained by the formation of nearly spherical cavities with strenghtened shells or walls of cement paste around the spherical expanded polystyren particles. This shell effect indicates a positive influence on the strength.
• the shell structure has an obvoius similarity with that which has been described above for air-voids with their positive consequences even in the fresh state such as increasing the particle density. In the density range tested i.e. 7001.200 kg/m the compessive strengths are 4,5-14,0 MPa. The increase in relative strength is greater than for
• thermal conductivity of the concrete As guidance values of the thermal conductivity of the concrete the following may be used:
• Example 1 Fraction 1-4 mm polystyren. 4-12 mm lightweight aggregate
• Example 2 Fraction 1-4 mm 80% lightweight aggregate and 20% polystyren, 4-12 mm lightweight aggregate.
• Example 2 indicates that it is possible to adjust the average density of an aggregate fraction in order to reduce the density of the concrete.
• Example 3 indicates that it is possible to reduce the cost of the concrete by using cheaper components.

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• 1983
  • 1983-10-05 SE SE8305474A patent/SE453181B/sv not_active IP Right Cessation
• 1984
  • 1984-10-02 AT AT84903680T patent/ATE49583T1/de not_active IP Right Cessation
  • 1984-10-02 EP EP84903680A patent/EP0181868B1/en not_active Expired - Lifetime
  • 1984-10-02 DE DE8484903680T patent/DE3481053D1/de not_active Expired - Lifetime
  • 1984-10-02 AU AU34355/84A patent/AU3435584A/en not_active Abandoned
  • 1984-10-02 WO PCT/SE1984/000327 patent/WO1985001499A1/en active IP Right Grant
  • 1984-10-03 IS IS2948A patent/IS1475B6/is unknown
• 1985
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  • 1985-10-24 FI FI854160A patent/FI854160A0/fi not_active Application Discontinuation
• 1986
  • 1986-04-04 RU SU864027341A patent/RU2026848C1/ru active
• 1988
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