WO1995011862A1 - Materiau de construction renfermant un ciment hydraulique et une matiere ligneuse enrobee a titre de matiere de charge - Google Patents

Materiau de construction renfermant un ciment hydraulique et une matiere ligneuse enrobee a titre de matiere de charge Download PDF

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Publication number
WO1995011862A1
WO1995011862A1 PCT/NZ1994/000120 NZ9400120W WO9511862A1 WO 1995011862 A1 WO1995011862 A1 WO 1995011862A1 NZ 9400120 W NZ9400120 W NZ 9400120W WO 9511862 A1 WO9511862 A1 WO 9511862A1
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WO
WIPO (PCT)
Prior art keywords
cement
coating
water
woody
fraction
Prior art date
Application number
PCT/NZ1994/000120
Other languages
English (en)
Inventor
Warwick Wyaat Duane
Original Assignee
Cretetech Development Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cretetech Development Limited filed Critical Cretetech Development Limited
Priority to AU80680/94A priority Critical patent/AU8068094A/en
Publication of WO1995011862A1 publication Critical patent/WO1995011862A1/fr

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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
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/525—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing organic fibres, e.g. wood fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/02—Conditioning the material prior to shaping
    • 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
    • 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
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • 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

Definitions

  • the present invention relates to improvements in and/or relating to cementitious building materials, a dry mix composition suitable for forming or forming part of such a cementitious building material, methods of forming such cementitious building materials (or a dry hydraulic cement/woody aggregate mix suitable therefor) and related downstream methods and procedures including any formed or moulded product set and/or cured.
  • Traditional building material compositions are known involving lignocellulistic material such as wood fibre or sawdust combined with cement.
  • the current manufacturing techniques for such compositions involve extensive steps to remove the wood sugars and other wood carbohydrates from the wooden material prior to the introduction and mixing with cement.
  • the presence of wood carbohydrates and probably other soluble or leachable inclusions or metabolites thereof inhibits the curing of the cement in the finished building mix. These steps to remove wood carbohydrates are both time consuming and costly.
  • the coating materials chosen however, do not provide in a final wet mix a substantial barrier for at least 5 hours after mixing with the cement containing wet fraction to movement of leachate from the woody material into the cement containing wet fraction nor of water from the cement containing wet fraction into the woody material.
  • DISCLOSURE OF INVENTION The present invention is directed to a method which enables the use of woody material that has not been pre-treated (to remove inclusions that will generate a cement set/cure problem or to resist uptake of water) other than a simple coating procedure adapted to ensure a substantial barrier for at least 2 hours after substantially homogeneous admixture with the hydraulic cement containing wet fraction. It is to this that the present invention is directed, ie; settable and self curing compositions capable of being formed or moulded and which generate a lightweight useable rigid structure once cured, the aggregate including or preferably being primarily or solely the coated woody material.
  • the present invention consists in a cementitious building material capable of being moulded by formwork or otherwise and of setting and self curing to provide a rigid cementitious structure, said material having a hydraulic cement containing wet fraction capable in time of first setting and then curing, and substantially homogeneously mixed in said cement containing wet fraction, a coated material fraction in the form of particles, shavings, fibres and/or the like of a woody material, said coating of said material having occurred prior to admixture with the cement containing wet fraction and being a coating with a material that provides a substantial barrier to the movement (I) of leachate from the woody material into the cement containing wet fraction and (II) of water from the cement containing wet fraction into the woody material for at least 5 hours after the substantially homogeneous mixing.
  • said coating results from mixing with a slurry, solution and/or emulsion of the coating material.
  • said coating material is a mineral or biological oil or a tar or a derivative thereof.
  • said coating material results from mixing with a liquid borne bitumen or bitumen derivative.
  • cementitious building material sets within a period of at least 2 hours and preferably 2 to 14 hours and most preferably from 5 to 8 hours.
  • said hydraulic cement containing wet fraction is a fraction at least primarily made up of a portland cement.
  • woody material is selected from the "woody” group consisting of wood wool, sawdust, bark, nuts, husks, savings, mulched waste wood, coconut husks, bamboo stems and slivers.
  • said wood material is of a particle size in the range 0.1mm to 100mm and most preferably 0.2mm to 10mm.
  • an additional fraction preferably also similarly pre-coated
  • other material may be substantially homogeneously mixed in with said cement containing wet fraction, for example, glass pieces, tyre pieces, glass or plastic fibres or rovings, or the like.
  • the coating of said woody material fraction is optionally at least substantially dry of water and/or solvents prior to being included in admixture with the cement containing wet fraction.
  • said building material is capable of setting within a period of from two to twelve hours and of being at least substantially cured by about 29 days.
  • the present invention consists in a self setting cementitious building material comprising a portland cement containing wet fraction, and an aggregate at least substantially provided in a woody material, said woody material having being coated by mixing with a slurry, solution and/or emulsion of a coating material, said coated material optionally having the coating substantially dry when admixed with the cement containing wet fraction, said coating being characterised in that it provides a substantial barrier to the movement (I) of leachate from the woody material into the cement containing fraction and (II) of water from the cement containing wet fraction into the woody material for at least 5 hours after the mixing.
  • the present consists in a method of forming a substantially rigid cementitious structure, said method comprising preparing a wood material as an "aggregate" by mixing the material in a physical form suitable to serve as an aggregate with a coating slurry, solution and/or emulsion capable of providing a coating on the aggregate to resist leaching of materials from the aggregate into the cement containing wet fraction and of water from the cement containing wet fraction into the aggregate, and optionally allowing the thus coated material to at least substantially dry, preparing with water and a cement a wet cement mix which optionally may include chemical or non chemical additives, mixing the coated aggregate with the prepared wet cement to provide a substantially homogeneous mix, forming or moulding the mix to a desired shape and allowing the onset of a set, optionally removing the product from the mould or form work, and thereafter allowing the material to cure to a substantially dry rigid cementitious structure.
  • the invention consists in a dry hydraulic cement/woody "aggregate" mix comprising in substantially homogeneous admixture a dry hydraulic cement and a woody material in the form of particles, shavings, fibres and/or the like, such material having a coating with a material that provides a substantial barrier to the movement (I) of leachate from the woody material into the cement containing wet fraction when the dry mix is mixed with water and (II) of water from the cement containing wet fraction when the mix is mixed with water into the woody material, such substantial barriers to the movements (I) and or (II) being for at least 5 hours after the inclusion of water.
  • said dry mix is one which when mixed with water is a cementitious building material as previously set forth.
  • the invention consists in, as a component for inclusion in a dry mix or cementitious product as previously defined, a coated woody material selected from particles, shavings, fibres and/or the like and the coating is sufficiently water insoluble as to provide for at least a period of 5 hours after exposure to water a substantial barrier to the movement (I) of leachate from the woody material into the wet cement and (II) of water from the wet cement into the woody material.
  • the invention is a settable composition formed as a substantially homogeneous mix of an aggregate component and of a wet cement component, wherein said aggregate component is an aggregate which at least substantially is of a woody material in a suitable aggregate physical form which has been coated by a mixing process with a coating material while the coating material has been water and/or organic liquid borne (whether as a slurry, solution or emulsion) but which at the time of the binary mixing is a substantially water insoluble coating, and which aggregate component optionally may include chemical additives, and wherein said wet cement component is of a hydraulic cement and water, and optionally with chemical and/or non-chemical additives, and wherein the proportions and the coating are such as to allow the composition to set and to subsequently cure to a substantially self supporting form.
  • said coating is of bitumen or a bitumen derivative.
  • said hydraulic cement is a portland cement.
  • composition is formed to a panel form.
  • said composition when cured has a density of from 720 to 1100kg/m3 or a Specific Gravity of from 0.72 to 1.1.
  • said composition when cured has a Specific Gravity of 1.05 to 0.72 and a corresponding Modulus of Elasticity of from 5.6 to 5.1 GPa (bending) and Modulus of Rupture of from 7.22 to 6.41 GPa (failure).
  • the present invention consists in a formed product resulting from the use of the method of the present invention or any of the cementitious building material in accordance with the present invention.
  • said product is in the form of a panel for a building.
  • Figure 1 is a photograph of a rectanguloid block of a self supporting cementitious material after initial set but prior to long term self curing, such a material having being formed as described in Example 1
  • Figure 2 is a similar arrangement as that described in relation to Figure 1 but this time relating to the composition of Example 2 which includes less portland cement content
  • Figure 3 is similar to that of Figure 2 but where the product has included as a chemical additive an aeration agent, the composition being described in example 3,
  • Figure 4 shows a set and self cured formed composition where the woody material has primarily being a particulate bark, it being seen that the product dries where lack of colouring agents as a chemical additive allows to a lighter form than the still uncured form depicted in Figures 1 through 3,
  • Figure 5 is a flow diagram showing the preferred process of a present invention.
  • woody material encompasses a number of different materials and examples include wood wool, sawdust, bark, nuts, husks, shavings, mulched waste wood, coconut husks, bamboo stems and slivers.
  • the term "coating" in relation to the woody aggregate material envisages a material capable of remaining as a coating when exposed to water for at least 5 hours (unlike the silicate and related products referred to in the aforementioned French Specification).
  • the present invention envisages the coating as being any suitable material preferably capable by delivery in an appropriate carrying liquid so that a simple mixing procedure as set out in Figure 5 can be performed.
  • the material is substantially water insoluble and can be dissolved in a carrier solvent or at least readily slurried or emulsified.
  • a preferred form of the material for the coating is one derived from a biological oil (for example, tall oil, linseed oil, paraffin oil, or derivatives thereof) eg;
  • FUNTCOTETM (a bitumen derivative/tall oil blend) of Shell New Zealand Limited or a bitumen or bitumen derivative material.
  • a preferred material which is a bitumen derivative is that product marketed as SLOWBREAK 1 " by Emoleum Limited in New Zealand.
  • SLOWBREAK 1 a bitumen derivative of Shell New Zealand.
  • other coating materials based on a mineral oil etc can be provided.
  • the coating material may optionally include emulsifying agents if necessary.
  • Reference herein to the coating being “dried” means that it is formed to an extent required such that it will largely remain in place during the mixing stage with the wet cement fraction and still provide the measure of impendence required for the migrations referred to.
  • the base material is a plastic mixture of mortar of a hydraulic cement or similar cement mixed with water and combined with suitable treated wood or similar lightweight "aggregate”.
  • this material In its plastic state this material can be poured, cold cast or moulded into a variety of forms which when appropriately cured result in stable and durable products appropriate to the needs of the construction and contracting industry.
  • An intrinsic feature of the product resides in the methodology of pre-treatment of the raw stock wood fibre, (or similar), used as the "aggregate”.
  • the raw material generally contains "sugar” based chemicals, or other, which when leached into the mortar tend to retard the set of hydraulic cements.
  • the raw material when dried tends to be highly water absorptive.
  • Wood based raw material also tends to be susceptible to attach by termites or similar predators, as well as by fungus or mould organisms.
  • raw material Prior to this treatment raw material may be either in a "natural" state or where precise density control of -finished product is indicated shall be kiln dried.
  • a preferred coating material in use is a derivative of bitumen known as
  • An alternative coating is based upon a "Tall Oil” (eg FLINTCOTETM - a bitumen derivative/Tall Oil blend).
  • Mix designs are based upon a mixture of cement, water, and a combination of selected treated fibre grades, and on occasion with the addition of a proportion of synthetic fibres.
  • Cement Any Portland Cement or blended Portland cement meeting an approved International Standard, eg; NZS, AUS, ACI, DIN, JAP, etc may be used although recommended dose rates may require variation in the case of some blended cements. However, this shall not restrict the use of other optional types of cement, eg; limestone cement, volcanic dust cements, etc alone or blended.
  • Cement is batched by weight, typical dosage preferably ranging from 300kg/m3 to 650kg/m3 depending on the apphcation but notwithstanding, cement contents outside this range may be used from time to time.
  • the W/C Ration shall lie in the range 0.4 to 0.6wAv(equiv vAv) depending on the intended apphcation.
  • ii) Water is batched by volume.
  • the aggregates shall be various grades of "coated” wood fibre or other similar material, not excluding synthetic materials. There are three common grades of wood fibre most preferred. a) “Wood wool” b) Wood “shavings” c) Sawdust d) Wood bark ii) Aggregate is batched by "bulk” volume.
  • the recommended mixer is the typical rotating paddle type used for mixing plaster. Generally the cement is initially combined with 2/3 of the batch water and the aggregate then added, mixed, and sufficient of the remaining water added to achieve the desired consistency.
  • Wood wool 500 litres
  • the product permits considerable versatility in design method, i) "Sandwich” construction using a low density infill variation with a thin (5mm) very high quahty skin cast on both faces. This would consist of a cement, SiKca fume mortar reinforced with nylon fibre producing a finish of very high "toughness” and durability. ii) A similar "infill” material in combination with the "external” steel or synthetic reinforcing method. hi) A bipart cladding slab with a low density exterior mix for insulation, and a higher density internal section for thermal mass storage. This combination could be designed to accommodate the climatic variations of the geographical region of intended use. The method would eliminate the need for "studs" in the building design, iv) Simulated "log cabin” using precast light weight planks placed horizontally.
  • Landscaping Utilities i) Decorative panel fencing ii) Ornaments and sculptures hi) Lightweight bricks of rock facsimiles.
  • Precast floor slabs with integral cast joists Surface resistance to abrasion maintained by appropriate high toughness skin. (Note water proof advantage over conventional "wood chip board”).
  • Fibre material such fibre glass, plant fibres, steel wool etc. Coloured oxides to alter colour of product.
  • Curing accelerant such as calcium chloride.
  • a composite material consisting principally of wood fibre and Portland cement with a density of approximately 720kg/m3 can be expected to have a thermal resistivity of approximately 6.5W/m/Kdeg. which compared with 6.9 for laminated pine planks. At a density of 1050kg/m3 a thermal resistance of 4 W/m/K is anticipated.
  • Nylon fibre 310 gms. (8.2kg/m3) [DuPont AR 20mm]
  • Nylon Fibre 310gm (8.21g/m3)
  • Nylon fibre 310 gm

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

Mélange binaire permettant d'obtenir un matériau de construction à base de ciment, l'un des constituants du mélange étant une fraction humide renfermant un ciment hydraulique et pouvant d'abord prendre et ensuite durcir à mesure que le temps passe, tandis que l'autre constituant du mélange binaire est une fraction de granulats composée principalement d'une matière ligneuse enrobée d'une matière sensiblement insoluble. De préférence, l'enrobage s'effectue dans un processus de mélange préalable où la matière d'enrobage est portée par de l'eau et/ou par un solvant organique. On permet à l'enrobage de sécher avant de réaliser le mélange binaire, et cet enrobage forme une barrière matérielle empêchant, pendant les 5 heures au moins qui suivent le mélange sensiblement homogène, toute infiltration dans la fraction humide renfermant le ciment, (i) du percolat en provenance de la matière ligneuse et, dans la matière ligneuse, (ii) de l'eau en provenance de la fraction humide renfermant le ciment.
PCT/NZ1994/000120 1993-10-28 1994-10-27 Materiau de construction renfermant un ciment hydraulique et une matiere ligneuse enrobee a titre de matiere de charge WO1995011862A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU80680/94A AU8068094A (en) 1993-10-28 1994-10-27 Building material containing a hydraulic cement and a coated woody material as filler

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NZ25008893 1993-10-28
NZ250088 1993-10-28

Publications (1)

Publication Number Publication Date
WO1995011862A1 true WO1995011862A1 (fr) 1995-05-04

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PCT/NZ1994/000120 WO1995011862A1 (fr) 1993-10-28 1994-10-27 Materiau de construction renfermant un ciment hydraulique et une matiere ligneuse enrobee a titre de matiere de charge

Country Status (3)

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AU (1) AU8068094A (fr)
WO (1) WO1995011862A1 (fr)
ZA (1) ZA948481B (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1006648C2 (nl) * 1997-07-23 1999-01-26 Karel Hermanus Stroethoff Kweekvijver en werkwijze voor het aanleggen hiervan.
RU2535578C1 (ru) * 2013-07-08 2014-12-20 Марина Владимировна Акулова Арболитовая смесь
WO2015136290A1 (fr) * 2014-03-12 2015-09-17 Enviromate Limited Matériau de construction et son procédé de fabrication
US10882785B1 (en) 2019-07-01 2021-01-05 Allnew Chemical Technology Company Producing cementitious materials with improved hydrophobicity and strength using reclaimed waste substances

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Patent Citations (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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DE555394C (de) * 1930-06-28 1932-07-21 Friedrich Winzer Verfahren zur Herstellung von Bodenbelag durch Mischung von impraegnierten Saegespaenen und Zement
DE687998C (de) * 1938-12-03 1940-02-10 Buesscher & Hoffmann Akt Ges Verfahren zur Herstellung von Daemmstoffen
FR888658A (fr) * 1942-11-30 1943-12-20 Procédé pour la fabrication de matériaux de construction en partant des déchets de bois avec du bitume et un liant hydraulique
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NL1006648C2 (nl) * 1997-07-23 1999-01-26 Karel Hermanus Stroethoff Kweekvijver en werkwijze voor het aanleggen hiervan.
RU2535578C1 (ru) * 2013-07-08 2014-12-20 Марина Владимировна Акулова Арболитовая смесь
WO2015136290A1 (fr) * 2014-03-12 2015-09-17 Enviromate Limited Matériau de construction et son procédé de fabrication
US10882785B1 (en) 2019-07-01 2021-01-05 Allnew Chemical Technology Company Producing cementitious materials with improved hydrophobicity and strength using reclaimed waste substances
WO2021003012A1 (fr) * 2019-07-01 2021-01-07 Allnew Chemical Technology Company Production de matériaux cimentaires présentant une hydrophobicité et une résistance améliorées à l'aide de déchets récupérés

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