WO1992018436A1

WO1992018436A1 - Method for producing a product made of a lightweight material, and material having controlled physical properties thereby obtained

Info

Publication number: WO1992018436A1
Application number: PCT/FR1991/000313
Authority: WO
Inventors: Gérard ASCHER
Original assignee: Ascher Gerard
Priority date: 1991-04-16
Filing date: 1991-04-16
Publication date: 1992-10-29
Also published as: EP0554251A1

Abstract

A method for producing a product made of a cellular material, wherein, to obtain a curable blend, at least one mineral and/or organic component is kneaded together with water and an aqueous solution of at least one blowing agent whereby a lightweight product containing air-filled cells of predetermined dimensions is obtained. This method is particularly suitable for producing products made of cellular concrete, ceramic material, plaster and polymer-concrete composite material.

Description

PROCESS FOR PRODUCING A PRODUCT MADE OF LIGHTWEIGHT MATERIAL AND MATERIAL HAVING CONTROLLED PHYSICAL PROPERTIES OBTAINED BY THIS PROCESS.

The present invention relates to a process for manufacturing a product made of cellular cellular material in which a curable mixture is prepared, characterized in that to prepare the curable mixture, at least one mineral and / or organic component is kneaded with water and an aqueous solution of at least one foaming agent (hereinafter also called foaming solution), said mixture is molded, allowed to harden and the product obtained is demolded.

The foaming agent is, in particular, a surfactant, for example an alkyl sulphate. This process makes it possible to obtain cellular materials. Indeed, by kneading the mineral and / or organic components in the presence of a foaming agent, air is introduced into the mixture. Thus, the materials obtained are lightened. By using well-defined proportions, it is possible to obtain a determined dimensioning of the cells and consequently a material offering significant weight advantages, combined with advantageous mechanical, thermal and phonic properties. This results in significant savings in material and, consequently, in manufacturing cost.

The present invention firstly relates to a process in which the curable material is a cellular composite mortar containing fibers and the cellular concrete obtained.

Cellular concretes are known; these are most often autoclave concretes obtained by aluminate reaction. It is also known to prepare them by mixing the various constituents of concrete with water and a foaming product, and thus to include air in the mortar. We can thus obtaining concretes of varying densities.

Furthermore, it is also known to introduce fibers into ^' traditional concrete.

The present invention relates to a cellular concrete containing fibers, which has particular properties.

The present invention therefore relates to a process in which the hardenable material is a cellular composite mortar containing fibers, characterized in that a mixture formed of the following constituents is subjected to kneading:

- 25 to 60% Portland type cement;

- 25 to 80% of siliceous sand or minerals, with an SiO content of at least

2 80%;

6 to 40% of a limestone or clay load with a particle size less than

80 micrometers;

- 0.5 to 5% of fibers having a length between 10 and 30 mm;

- 0.05 to 0.8% of a foaming agent;

- 15 to 40% of water, the above proportions being given by weight relative to the total weight of the kneaded constituents to obtain a cubic meter of dry solidified product.

These proportions generally correspond, per cubic meter of dry material, to a dosage comprising from 250 to 600 kg of cement, from 250 to 800 kg of sand or siliceous minerals, from 60 to 400 kg of limestone or clay filler, from 0, 75 to 8 liters of foaming agent and 150 to 400 liters of water.

The cement used can be white or gray cement.

According to the present invention, the foaming agent is preferably an anionic agent, for example an alkyl sulfate, and, in particular, the solution sold under the trade name "TEC 3" by the company "WINTEC".

The fibers used can be of different natures: polypropylene, polyester, glass, vegetable, metal, rock; these are, in particular, acrylic fibers.

It is also possible to introduce into the mixture during kneading coloring additives, in the form of powders or liquids and / or setting accelerators, fluidizers, water reducers or sealers. According to the need, it is also possible to introduce synthetic resins of epoxy or polyester type, for example. polyvinyl ester example, in proportions of 1 to 15% by weight calculated as defined above.

Kneading allows, in known manner, to foam the foaming agent and to introduce air into a mortar. According to the present invention, it is preferably carried out using a kneading device having peripheral speeds of between 0.5 and 10 meters / second. The mixing time is generally between 2 and 20 minutes.

The foaming agent used can be introduced directly into the kneading mixture. It can also be introduced in the form of foam prepared beforehand.

One can either introduce directly into the kneading mixture all the water required, or, first, prepare by mixing a wet mortar using a fraction of the water, then, in a second time, add the rest of the necessary water.

The viscosity of the paste obtained after kneading is controlled according to the desired flowability by introducing, a determined amount of water and foaming agent. If necessary, it can be appealed commonly used plasticizers.

The dough obtained is then poured into shapes or profiles, in formwork or molds or in the ground, its speed of solidification being functional. of composition. After setting and demoulding, the material thus produced has, depending on the composition, a concrete or faux stone appearance, the coloring of which can be adjusted beforehand. If necessary, this same paste can be poured into elements in which metal frames have been previously placed.

After hardening, during which the stability of the mixture is obtained, it is found that the material has a closed macroporosity structure in which the air cells are uniformly calibrated and where the distributed fibers provide effective reinforcement of the matrix.

The present invention also relates to the cellularized material loaded with fibers obtained by the process described above, characterized in that it has a dry density of between 0.9 and 1.4. This material generally has a compressive strength between 4 and 30 MPa and a flexural strength between 2 and 6 MPa, these resistances being measured respectively according to standards NF P15-451 and P15-403.

Measurements of thermal conductivity A carried out according to standard NF X10-021 have shown that said conductivity \. is between 0.255 and 0.48 W / m. ° K depending on the density of the material.

The dimensional variation of the material according to the invention between extreme conventional states, measured according to standard NF 14-304 is between 0.020% and 0.200%. Water absorption measurements by capil¬ larity according to standard NF 14-306 were carried out in measuring the quantity of liquid water absorbed by one face of the material. They are between 10 and 110 g / dm ² and show the ability of the material according to the invention to withstand the weather. This ability was confirmed by measuring the water diffusivity using a gammameter, according to experimental conditions, which made it possible to note a sorp- tivity between 0.68 and 19.10 "ms ^{~ 5} .

Durability tests were carried out by subjecting the material to freeze / thaw cycles according to standard NF B10-513. Resistances of a minimum of 150 cycles and an average of 240 cycles were obtained.

It has been found that the structure of the composition makes it possible to obtain characteristics of surface hardness and penetration force suitable for any use of an element in a concrete type of structuring wall and makes it possible, in particular, to perform in the element a screwing or nailing, whose resistance to tearing is perfectly satisfactory. The structure of the material allows suitable penetration of the screws and their driving in by turning with a screwdriver; a thread is created in the material, which makes it possible to obtain perfect support for the matrix and the screw without destruction beyond its penetration diameter. This observation is confirmed by the fact that if you unscrew and screw it back in the same hole, although there is a slight enlargement on the surface of the section of the hole, the internal perimeter maintenance of the hole allows a screwing , which can be operated with the thread created in the matrix.

It can be seen that, during penetration during screwing, the destruction of the matrix of the material on the section of the screw causes the formation of matrix waste which comes, at the same time as it penetrates, a self-locking reinforcement of material between the threads of the screw and the available volume of the neighboring macroporosities, reinforcement which contributes to the good behavior of the wall.

Since the internal screw pitch is formed at the time of penetration, the use of screws of different shapes is possible both for "Parker" type screws and for wood screws.

For those skilled in the art, the importance of this invention in building and public works appears obvious, since a pre-drilling and pegging of this material comparable to concrete is no longer necessary. This considerably facilitates the implementation of the holes and the fixing of hooking elements. Likewise, the possibility of driving nails directly into this material without bursting, with compatible support for suitable use of nailing, allows very numerous applications for the user which will save time. important and will no longer be obliged to use specific accessories.

As with wood, for example, only the sections of the parts used, the material or the size of the nails or screws or their pitch and the driving distances, condition the axial or perpendicular resistance values obtained with the load. .

In addition, the material remains compatible with a pre-drilling or an anchor installation which operates under the same conditions as with a traditional concrete or mortar. It also remains likely to receive seals as in any concrete product.

Another aspect of the invention consists in the fact that, in addition to the advantages described above, this same material is manually sawn to be cut like a piece of wood which is particularly appreciable in the case of a concrete type material for which this operation usually requires significant mechanical means. In addition, which is an additional advantage, the conditions of production of this material allow its manufacture both on site or on site as in an industrial prefabrication structure, which makes its use easy in the most varied fields of building and public works. This material makes it possible to constitute both walls and partitions as floors and floors, or all shaped parts, in one or more elements. Multiple uses of the material according to the invention are possible. An example of a specific application, allowing different technical and practical advantages to be used, has been developed for the production of versatile and multi-purpose elements. These prefabricated elements are made up of different types of profiles made in great length (about 3 meters); these profiles are then cut to the desired use length to have sections whose weight allows manipulation by a single man. For example, a piece 1.50 m long can, given the densities indicated, weigh less than 40 kg. These different types of profiles are illustrated in Figures 1 to 6 of the accompanying drawing. Figure 1 shows a U-shaped profile 1 with two branches of equal length. Figures 2 and 3 show profiles 2 and 3 also in U, the base of which has notches. Figures 4 to 6 show U-shaped profiles, 4 to 6 respectively, whose branches have different lengths and whose bases have different notches on the side of the shortest branch. These profiles, which benefit from the technical characteristics of the material according to the invention, are, moreover, designed to be used horizontally or vertically and suitable for all uses by assembly, gluing, screwing or nailing by constituting, either directly finished products ( gutters, posts, chaining, etc.), or pre-formwork lost in which is then poured traditional concrete, with or without reinforcement. These pre-forms can constitute door and window frames and, in general, all angles or walls onto which a piece of wood or metal is to be screwed, such as for example joinery, window frames, locksmiths. Many assemblies or assemblies using these same elements are also made pos¬ sible thanks to the ease of manual cutting of the material which also allows vertical or horizontal embedding on the three sides of the parts. All assembly systems requiring closure of the open polygonal section of an element which must be dismountably closed, the section polygon, are solved by the simple screwing of a plate of the same material on the uprights of the element.

The aspects of these parts can be, as indicated above, adjusted in coloring or in surface condition.

A second object of the present invention is a process for manufacturing a product made of cell site composite material in which the curable mixture is a slip, characterized in that the following constituents are subjected to kneading: - 29 to 79% ceramic powder; - 20 to 70% water;

0.2 to 1% of a solution of at least one foaming agent, the above proportions being given by weight relative to the total weight of the components kneaded together to obtain a cubic meter of dry solidified product.

The ceramic powders are, in a known manner, based on clay containing variable amounts of kaolinite and / or miolite.

The solution of foaming agent (s) can be introduced directly into the mixture during kneading; it can also be introduced in the form of foam prepared beforehand.

We can either introduce all of the necessary water directly into the kneading mixture, or, firstly, prepare a slip using a fraction of the water, then in a second time, add the rest of the necessary water.

The viscosity of the paste obtained after kneading is controlled according to the desired flowability by introducing quantities of water and foaming solution determined.

The dough obtained is then poured into molds of any shape or configuration. Its solidification speed varies from 3 to 15 minutes depending on its composition.

After setting and demoulding, the material obtained consists of a cellularized raw ceramic, the density of which varies according to the composition. The material is then dried to remove any excess water. Drying can be done at room temperature or in a dryer. Depending on the drying conditions, the drying time is more or less long. The material obtained is a material with a closed porous structure in which the air-containing cells are homogeneously distributed and which no longer undergoes any variation in volume with respect to the initial casting volume.

The material thus formed can be brought to a firing temperature above 800 ° C, to be ceramized. It then consists of a cellularized ceramic refractory material which can be used both for the manufacture of insulating refractory bricks as well as light ceramics or so-called "technical" ceramics. Said ceramic materials offer, in addition to their refractory properties, significant advantages linked to the presence of this porosity which gives them complementary insulating properties, in particular by a reduction in the thermal transfer values.

The present invention also relates to the ceramized cellularized material described above, characterized in that it has a dry density of between 0.3 and 1.4. These materials after ceramization, generally have a compressive strength of between 5 and 10 bars for a material having a density of 0.35 to 0.5 and 10 to 15 bars for a material of density between 0.5 and 0 , 6. The process for preparing refractory ceramic material according to the invention makes it possible to reduce industrial costs and pollution. Indeed, in current practice, these materials are manufactured by introducing into the composition, before calcination, a pore-forming agent constituted by plants, for example by wood shavings, and also plaster, to promote setting.

The calcination causes the formation of fumes from the wood-plaster mixture which are very polluting for the atmosphere, and, to avoid pollution, means of filtration, recovery and treatment. very large and expensive fumes are necessary. The present invention avoids having to use these means.

Furthermore, in the process of the prior art, the destruction of the porogen requires a very large energy expenditure and a very long time in the oven. In addition, it is necessary to cool the material very slowly after calcination to avoid thermal shock. The process of the present invention also has the advantage of allowing the manufacture of traditional or technical ceramics, lightened and having improved thermal transmission properties. In addition, the process allows effective control of the density of the finished product.

A third object of the present invention is a process for manufacturing a product in which the curable mixture is a plaster, characterized in that a mixture formed of the following constituents is subjected to kneading:

- 45 to 60% plaster;

O to 15% of mineral and / or organic filler;

- O to 2% organic and / or mineral fibers;

- 45 to 60% water;

0.1 to 1% of a solution of at least one foaming agent, the above proportions being given by weight relative to the total weight of the kneaded constituents ensem¬ ble to obtain a cubic meter of dry solidified material.

In the case of the manufacture of cel¬ lularized plaster without fibers and without additional fillers, these proportions generally correspond, per cubic meter of solidified material, to 650 to 700 kg of plaster. 550 to 590 kg of water and 0.650 to 0.750 kg of solution of at least one foaming agent.

According to the present invention, the solution of foaming agent (s) is preferably that marketed under the trade name "TECPLATRE" by the company INTEC.

The fillers used can be mineral fillers such as silica, silicoaluminates for example calcined kaolin, sand, quartz or shales and / or organic fillers such as a vegetable filler or polymers.

The fibers used can be mineral fibers, for example rock, glass, metal or organic fibers, for example vegetable fibers, such as wood fibers or cellulose fibers, polypropylene, polyester. More particularly, acrylic fibers are used.

It is also possible to introduce into the mixture additives such as dyes in the form of powders and / or liquids, setting accelerators, thinners, water reducers or sealants. The proportion of additive (s) introduced does not exceed 1% of the total weight of the mixture including water. The solution of foaming agent (s) is preferably introduced directly into the mixture during kneading, together with the water.

The viεcoεité of the dough obtained after kneading is controlled by varying it within the limits determined above, the amounts of water and solution of foaming agent (s) introduced.

The dough obtained is then poured into molds of all shapes or configurations. Its solidification speed varies between 3 and 5 minutes depending on the composition and the quality of the plaster used. The material obtained is then dried, either at room temperature, or, to speed up the drying process, by steaming at a higher temperature. After drying, a material with a closed porous structure is obtained in which the cells containing air are distributed in a homogeneous manner and which has not undergone any variation in volume (no shrinkage) relative to the initial casting volume. Due to their manufacturing process, the materials according to the invention have a lower density than that of traditional plaster and improved insulating properties, in particular of thermal insulation. The present application also relates to the cellular plaster obtained by the above process, characterized in that it has a density between 0.7 and 0.85 measured dry.

In the case where the plaster has a density of 0.7 and contains neither filler nor fiber, the cellular plaster generally has a compressive strength of between 1.5 and 3 MPa and a resistance to the bending of between 0.7 and 1.3 MPa depending on the composition of the kneaded mixture. When the material contains fillers and, more particularly, fibers, the mechanical properties and, more particularly, water repellency are improved.

Lightweight (or cellular) plaster containing fibers has the advantage of being a material in which screws can be placed directly, without the need for ankles. Plaster containing fibers has properties of tearing or shearing which are very superior (the improvement can reach + 50%) than those obtained under the same conditions with a traditional plaster. In addition, plaster containing fibers has a ductility much higher than that commonly observed for this kind of plaster material. The plaster according to the invention containing fibers is therefore of great interest in the production of anti-seismic walls. This last property of light plaster containing deε fibers can be clearly demonstrated on its own or in combination with supports of the cardboard honeycomb type to constitute partitions benefiting from large capacity for deformation at break.

The advantage of the plaster manufacturing process according to the invention is that it makes it possible to reduce the amount of plaster necessary for the manufacture of one cubic meter of material by approximately 30% and to reduce the amount of energy required for elimination. water of constitution, since the material contains less material and consequently, less water to be eliminated per cubic meter manufactured. We can therefore either reduce the drying temperature in an oven, or the quantity of energy used per unit of temperature.

In addition, we have found that by using light non-fiber plaster to serve as an imprint for the casting of ceramic slurry, we obtain a surface quality quality identical to that of traditional plaster and that we could adjust the sorptivity of the walls thanks to the porosity of the materials. It is thus possible to accelerate the speed of setting of the slip. It is therefore possible to obtain a significant improvement in the productivity of the molds, since they can be used with faster rotation.

The fourth object of the invention is a process for manufacturing a cellular material in which the hardenable mixture is based on an unsaturated polyether resin, characterized by the fact that the following constituents are mixed and kneaded: - 15 to 20% of unsaturated polyester resin;

- 0.027 to 0.03% of crosslinking catalyst of the polyether resin;

- 50 to 70% of mineral filler in the form of powder with a particle size less than 80 micrometers;

- 13 to 20% of a solution of at least one foaming agent, the above proportions being given by weight relative to the total weight of the mixed mixtures to obtain a cubic meter of dry solidified product.

Polyester resins which can be used according to the invention are, for example, the phenolic resin sold under the trade name "NEOXIL 421 TA 12" by the company "DSM-Resin". The polyester resins are advantageously used in pre-accelerated form. The catalyst used can be any known catalyst for crosslinking unsaturated polyether resin.

The mineral fillers used can be of variable composition and be in the form of more or less fine powder. They are, for example, made up of limestone, clay or quartz powders or recovered minerals such as marble powder.

According to the present invention, the foaming solution is preferably that marketed under the trade name "TECRESINE" by the company "INTEC". In the case of the material based on resin loaded with marble powder, the portions defined above generally correspond, per cubic meter of material solidified to 1400 to 1600 kg of marble powder with a particle size of less than 80 micrometers , to 80 to 100 kg of unsaturated polyester resin, to 1.6 to 2 kg of catalyst, 100 to 120 kg of foaming solution.

The soft solution can be introduced directly into the mixture during kneading. It can also be introduced in the form of mousεe prepared beforehand.

Preferably, the foaming solution with the mineral fillers is firstly introduced into the mixer, then, secondly, the resin and its catalyst are added. The viscosity of the dough obtained after kneading is adjusted according to the desired flowability by introducing a greater or lesser amount of wetting solution within the limits determined above. The paste obtained is then poured into molds of any shape or configuration in which a layer of gelcoat has previously been applied.

The speed of solidification of the material varies from 2 to 12 hours depending on its composition. Preferably, in order to speed up the setting and the crosslinking reaction, the mold filled with the material is placed in a ventilated chamber at a stabilized temperature of between 20 and 25 ° for at least 4 hours. After setting and demoulding, the material thus produced is, depending on the composition, in the form of a material of the resin concrete type, loaded and cellu¬ larized, the density of which is a function of the proportions of the components of the kneaded mixture. The material thus formed has a closed porous structure in which the air cells are distributed in a homogeneous manner and it has not undergone any volume variation with respect to the initial volume of casting. The porosity of the material has the advantage, in addition to its lightening, of giving it properties. insulating, in particular thermal insulation.

The present invention also relates to the cellularized material obtained by the process described above, characterized by the fact that it has a density at εec of between 1.5 and 1.7.

This material, after polymerization, generally has a compressive strength of between 30 and 40 MPa and a flexural strength of between 9 and 14 MPa for a material with a density of 1.6, therefore very satisfactory mechanical characteristics for the most uses.

The present invention also has the advantage of allowing significant savings in manufacturing costs compared to materials of the same nature, not lightened.

The economy is due to the reduction therefore in the reduced quantity of filler and especially of resin used for the manufacture of a cubic meter of material. Thus, according to the invention and taking into account the fact that the resin has a cost equal to approximately 100 times that of the filler and that, compared to a material of the same nature and not lightened, the difference in quantity of base material used is on average 30% lower for a cubic meter of finished material, we can calculate that the cost of this light loaded resin material represents a saving of raw material of the same importance, that is to say between 25 and 37% . The examples given below, by way of nonlimiting illustration, will allow a better understanding of the invention.

EXAMPLE 1 - Preparation of a cellular concrete loaded with fibers. We have prepared a composition, comprising the following components for a cubic meter of material: - CPA 55 gray cement 400.00 kg

- Rhine silica sand 660.00 kg

- Limestone charge (powder with grains at most 80 micrometers) .... 80.00 kg - Foaming solution marketed under the trade name

"TEC 3" by the company "INTEC" 0.80 kg

- Water 260.00 kg

- Acrylic fibers (24 mm long) 5.00 kg 200 liters of the composition were kneaded for 8 minutes in a kneader having a peripheral speed of 4.87 meters per second.

4 x 4 x 16 cm size test pieces were molded. We measured after 28 days, on the dry material, the density which is 1.34.

We also carried out the following:

1) Measurement at break according to standards NF P15-451 and NF P15-403 respectively: - Compression: 9.8 MPa - Bending: 3.1 MPa

2) Studding

On this same material was carried out, using a hammer, the driving of a twisted steel nail of 3.8 mm in diameter, with a length of 90 mm, driven in, according to the specifications, 50 to 80 mm. The nailing was carried out 30 mm from the lower outer edge of the concrete block. A vertical force is exerted on the protruding part of the nail. It has been observed that the load thus applied to the nail has always caused it to flex on the projecting part, before the material surrounding the nail is torn off. For an 80 mm drive, we applied up to 180 kg and for a 50 mm drive, up to 117 kg without having any tearing of the nail or the material surrounding it, the test ending with the bending of nail. 3) Screwing

In this same concrete, we screwed, using a manual screwdriver, a screw of 5 mm in diameter, and 60 mm in length; this screw was screwed, selo esεais, εur 30 and 50 mm. The screwing was carried out 100 mm from the lower outer edge of the block. O exerts a vertical force on the projecting part of the screw. It has been observed that the load applied vertically on the screw has always caused it to flex on the projecting part, before the material tearing which surrounds the screw.

For a penetration of 50 mm, we applied up to 310 kg in axial force and more than 150 kg in transverse force and for a depression of 30 mm, d 150 kg in axial force and 25 kg in transverse force εans without have no tearing of the screw or of the material surrounding it, the test ending with the bending of the screw.

EXAMPLE 2 Preparation of a lightened slip.

A composition was prepared comprising the following constituents per cubic meter of finished material: - Ceramic powder 600 kg

- Water 420 kg

- Foaming solution marketed under the trade name

"TEC 3" by the company "WINTEC" 3.9 kg 30 liters of the mixture were kneaded for minutes in a kneader having a peripheral speed of 4.87 meters per second. 21 x 7 x 28 cm test pieces were molded. We measured after day, on the material previously dried at a temperature of 90 ° C., the density which is 0.60.

The material was then brought to the oven at a temperature above 800 ° C., so as to obtain a ceramic product. The density measured after cooking is 0.50 and the mechanical resistance to compression rupture is 12 bars.

EXAMPLE 3 Manufacture of a cellular plaster containing fibers.

A composition was prepared comprising the following components for a cubic meter of finished material.

- Industrial plaster B 15 5.710 kg - Fine acceleration plaster DH 15 0.570 kg

- Water 5.340 kg

- Silica sand 00 0.350 kg

- Wet vegetable fibers 1/1 ..., 0.180 kg

- Foaming solution sold under the trade name

"TECPLATRE" by the company "WINTEC" 0.007 kg

10 liters of the composition were kneaded for 30 seconds in a kneader having a peripheral speed of 4.87 meters per second. A test specimen of

7 x 7 x 28 cm. It was then measured after 7 days, on a material previously dried at 35 ° C., the density which is 0.84. The mechanical resistance to rupture at compression is 2.88 MPa and the mechanical resistance to rupture under flexural tension is 0.7 MPa. EXAMPLE 4 - Resin concrete.

A composition was prepared comprising the following components for a cubic meter of finished material: Marble powder having a particle size less than 80 micrometer 1500 kg

Polyeεter resin sold or trade name

"NEOXIL 421 TA 12" 80 kg Catalyzer sold under the trade name "BUTANOX" 1.8 kg Foaming solution sold under the trade name "TECRESINE" by the company "WINTEC" 120 1

30 liters of the composition were kneaded for 4 minutes in a kneader having a peripheral speed of 2.80 m / second.

4 x 4 x 16 cm test pieces were prepared by molding. The density, which is 1.68, was then measured after 7 days. The compressive strength is 36 MPa and the flexural strength 12 MPa.

Claims

CLAIMS 1 - Method for manufacturing a product in cellular composite material in which a curable mixture is prepared, characterized in that to prepare the curable mixture, at least one mineral and / or organic component is kneaded with water and an aqueous solution of at least one wetting agent, said mixture is molded, it is allowed to harden and the product obtained is demolded. 2 - Process according to claim 1, in which the hardenable material is a cell composite mortar containing fibers, characterized in that a preparation formed from the following constituents is kneaded: 25 to 60% of cement of Portland type;

- 25 to 80% of sand or siliceous minerals with an SiO content of at least 80%; 6 to 40% of a limestone or clay load with a particle size less than

80 micrometers;

- 0.5 to 5% of fibers having a length between 10 and 30 mm;

- 0.05 to 0.8% of a stabilized foaming agent; - 15 to 40% of water, the proportion shown below being given in weight relative to the total weight of mixed ingredients mixed together to obtain a cubic meter of solidified product. 3 - Process according to claim 2, characterized in that the cement is white or gray cement.

4 - Method according to one of claims 2 or 3, characterized in that one introduces danε the mixture in the course of kneading the coloring additives and / or setting accelerators, deε fluidifiers, water reducers or sealers.

5 - Method according to one of claims 2 to 4, characterized by the fact that synthetic resin of epoxy or polyester type is introduced in proportions ranging from 1 to 15% by weight, calculated as defined in claim 1.

6 - Method according to one of claims 2 to 5, characterized in that the mixing is carried out using a mixing device having peripheral speeds between 0.5 and 10 meters / second.

7 - Process according to claim 6, characterized in that the mixing time is between 2 and 20 minutes. 8 - Process εelon one of claims 2 to 7, characterized in that one introduces the foaming agent directly danε the mixture in the course of kneading.

9 - Process according to one of Claims 2 to 8, characterized in that the soft agent is introduced, or a form of foam prepared beforehand.

10 - Process εelon one of claims 2 to 9, characterized in that one introduces directly danε the kneading mixture the fraction of water necessary in one or more times.

11 - Material with controlled physical properties obtained by the process according to one of claims 2 to 10, characterized by the fact that it has a dry density of between 0.9 and 1.4.

12 - Material with physical properties controlled according to claim 11, characterized in that it has a compressive strength between 4 and 30 MPa and a flexural strength between 2 and 6 MPa.

13 - Process ε according to claim 1, danε which the curable mixture is a slip, characterized in that the following constituents are subjected to kneading:

- 29 to 79% ceramic powder; - 20 to 70% water;

- 0.2 to 1% of a solution of at least one foaming agent, the above proportions being given by weight relative to the total weight of the kneaded components together to obtain a cubic meter of solidified product εec.

14 - Process according to claim 13, characterized in that the solution containing at least one foaming agent is introduced directly into the mixture during kneading.

15 - Process according to claim 13, characterized in that the solution containing at least one foaming agent is introduced in the form of a foam prepared beforehand. 16 - Method according to one of claims

13 to 15, characterized in that all the necessary water is introduced directly into the kneading mixture.

17 - Method according to one of claims 13 to 15, characterized in that a slurry is prepared in a first temperature by kneading using a fraction of water, then in a second temperature, we add the reεte of the necessary water.

18 - Method according to one of claims 13 to 17, characterized in that the material obtained by kneading is brought to a baking temperature above 800 ° C to be ceramics.

19 - Material prepared by the method of claim 18, characterized in that it has a density at εec compriεe between 0.3 and 1.4.

20 - Material according to claim 19, characterized by the fact that it has a resistance to compression of between 5 and 10 bars for a density of 0.35 to 0.5 and from 10 to 15 bars for a density of between 0.5 and 0.6 . 21 - Process according to claim 1, in which the curable mixture is a plaster, characterized in that the following constituents are subjected to kneading:

- 45 to 60% plaster; - O to 15% of mineral and / or organic filler;

- 0 to 2% organic and / or mineral fibers;

- 45 to 60% water;

0.1 to 1% of a solution of at least one foaming agent, the above proportions being given by weight relative to the total weight of the constituents kneaded together to obtain a cubic meter of solidified product εec. 22 - Manufacturing process according to the claim 21, characterized in that the foaming agent solution is introduced directly into the mixture during kneading.

23 - Method according to one of claims 21 or 22, characterized in that the mineral filler is εilica or an εilicoaluminate and the organic filler is a vegetable filler or a polymer.

24 - Method according to one of claims 21 to 23, characterized in that the fibers are rock fibers, glass, metal, wood or cellulose fibers, polypropylene, polyester, and, preferably, acrylic fibers.

25 - Material prepared according to one of claims 21 to 23, characterized in that it has a density between 0.7 and 0.85, measured dry. 26 - Material according to claim 25 having a density of 0.7 and containing no fiber, n filler, characterized in that it has a compressive strength between 1.5 and 3 MPa and a flexural strength between 0.7 and 1.3 MP depending on the composition of the kneaded mixture.

27 - Process according to claim 1, in which the hardenable mixture is based on unsaturated polyester resin, characterized in that the o subjects the following constituents to kneading:

- 15 to 20% of unsaturated polyester resin;

- 0.027 to 0.03% of crosslinking catalyst of the polyester resin;

- 13 to 20% of a solution of at least one foaming agent, the above proportions being given in weight relative to the total weight of the constituents kneaded together to obtain a cubic meter of dry solidified product.

28 - Process according to claim 27, characterized in that the mineral filler is limestone, clay or quartz.

29 - Method according to one of claims 27 or 28, characterized in that the solution of foaming agent (s) is introduced directly into the mixture during kneading. 30 - Method according to one of claims

27 or 28, characterized in that the solution of foaming agent (s) is introduced in the form of foam prepared beforehand.

31 - Process according to claims 27 to 30, characterized in that the agent solution (ε) is first introduced into the mixer foaming with mineral fillers, then, in a second step, the resin and its catalyst are added.

32 - Cellularized material obtained by the method of one of claims 27 to 31, characterized in that it has a dry density between 1.5 and 1.7.

33 - Material according to claim 32, having a density of 1.6, characterized in that it has a compressive strength between 30 and 40 MPa and a flexural strength between 9 and 14 MPa.