WO2000002826A1 - Construction element - Google Patents
Construction element Download PDFInfo
- Publication number
- WO2000002826A1 WO2000002826A1 PCT/AU1999/000555 AU9900555W WO0002826A1 WO 2000002826 A1 WO2000002826 A1 WO 2000002826A1 AU 9900555 W AU9900555 W AU 9900555W WO 0002826 A1 WO0002826 A1 WO 0002826A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- cementitious composition
- lightweight
- construction element
- amount
- cementitious
- Prior art date
Links
- 238000010276 construction Methods 0.000 title claims abstract description 64
- 239000000203 mixture Substances 0.000 claims abstract description 110
- 239000010455 vermiculite Substances 0.000 claims abstract description 35
- 229910052902 vermiculite Inorganic materials 0.000 claims abstract description 35
- 235000019354 vermiculite Nutrition 0.000 claims abstract description 35
- 238000000034 method Methods 0.000 claims abstract description 27
- 229920002678 cellulose Polymers 0.000 claims abstract description 23
- 239000001913 cellulose Substances 0.000 claims abstract description 23
- 239000011236 particulate material Substances 0.000 claims abstract description 22
- 239000000463 material Substances 0.000 claims abstract description 21
- 239000011347 resin Substances 0.000 claims abstract description 21
- 229920005989 resin Polymers 0.000 claims abstract description 21
- 239000004568 cement Substances 0.000 claims abstract description 19
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 17
- 229920003086 cellulose ether Polymers 0.000 claims abstract description 15
- 238000005266 casting Methods 0.000 claims abstract description 12
- 239000004848 polyfunctional curative Substances 0.000 claims abstract description 9
- 239000010438 granite Substances 0.000 claims abstract description 6
- 229920000642 polymer Polymers 0.000 claims abstract description 5
- 235000010980 cellulose Nutrition 0.000 claims description 22
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 19
- 239000010881 fly ash Substances 0.000 claims description 14
- 238000002156 mixing Methods 0.000 claims description 11
- 239000011324 bead Substances 0.000 claims description 9
- 239000004576 sand Substances 0.000 claims description 6
- 239000011449 brick Substances 0.000 claims description 5
- 238000002360 preparation method Methods 0.000 claims description 5
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical group CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 claims description 4
- 239000011121 hardwood Substances 0.000 claims description 4
- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 claims description 4
- 235000010979 hydroxypropyl methyl cellulose Nutrition 0.000 claims description 4
- 239000001866 hydroxypropyl methyl cellulose Substances 0.000 claims description 3
- UFVKGYZPFZQRLF-UHFFFAOYSA-N hydroxypropyl methyl cellulose Chemical group OC1C(O)C(OC)OC(CO)C1OC1C(O)C(O)C(OC2C(C(O)C(OC3C(C(O)C(O)C(CO)O3)O)C(CO)O2)O)C(CO)O1 UFVKGYZPFZQRLF-UHFFFAOYSA-N 0.000 claims description 3
- 229920001296 polysiloxane Polymers 0.000 claims description 3
- 239000011122 softwood Substances 0.000 claims description 3
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical group [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 claims description 2
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 2
- 239000004793 Polystyrene Substances 0.000 claims description 2
- 239000011398 Portland cement Substances 0.000 claims description 2
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 2
- 239000001110 calcium chloride Substances 0.000 claims description 2
- 229910001628 calcium chloride Inorganic materials 0.000 claims description 2
- 239000004571 lime Substances 0.000 claims description 2
- 229920002223 polystyrene Polymers 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 11
- 238000001125 extrusion Methods 0.000 description 10
- 238000009472 formulation Methods 0.000 description 5
- 239000000945 filler Substances 0.000 description 4
- 239000002952 polymeric resin Substances 0.000 description 4
- 229920003002 synthetic resin Polymers 0.000 description 4
- 239000004615 ingredient Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- 229920001479 Hydroxyethyl methyl cellulose Polymers 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229920003091 Methocel™ Polymers 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 238000005056 compaction Methods 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 239000004567 concrete Substances 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 238000007429 general method Methods 0.000 description 2
- 229910052618 mica group Inorganic materials 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 244000166124 Eucalyptus globulus Species 0.000 description 1
- 229920002153 Hydroxypropyl cellulose Polymers 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 1
- 235000011613 Pinus brutia Nutrition 0.000 description 1
- 241000018646 Pinus brutia Species 0.000 description 1
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 229920003090 carboxymethyl hydroxyethyl cellulose Polymers 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 125000001033 ether group Chemical group 0.000 description 1
- 235000010944 ethyl methyl cellulose Nutrition 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000009970 fire resistant effect Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 229920013819 hydroxyethyl ethylcellulose Polymers 0.000 description 1
- 239000001863 hydroxypropyl cellulose Substances 0.000 description 1
- 235000010977 hydroxypropyl cellulose Nutrition 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 229920003087 methylethyl cellulose Polymers 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 150000002978 peroxides Chemical group 0.000 description 1
- -1 preferably Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 description 1
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 description 1
- 239000010878 waste rock Substances 0.000 description 1
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
- C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
- C04B18/08—Flue dust, i.e. fly ash
-
- 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
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
-
- 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
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/10—Accelerators; Activators
- C04B2103/12—Set accelerators
-
- 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
- C04B2111/54—Substitutes for natural stone, artistic materials or the like
- C04B2111/542—Artificial natural stone
-
- 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 construction elements.
- the invention relates to a formulation for producing a lightweight cementitious composition using a cellulose particulate material, methods for the manufacture of the cementitious composition and a construction element produced from the cementitious composition.
- the invention also relates to a lightweight construction element which simulates the appearance of granite.
- cement blocks and panels are commonly used in the construction industry. As a building material, cement blocks and panels are typically heavy making it difficult to lift, move and place the cement blocks or panels when constructing structures. It is therefore desirable to utilise strong lightweight cementitious compositions and concrete for use in construction elements for the building industry which preferably have good acoustic and fire resistant properties, are strong, durable and affordable.
- Another form of the invention relates to a resin based construction element which simulates the appearance of granite and can be used in building products requiring such an appearance but required to be inexpensive and lightweight.
- a lightweight cementitious composition comprising:
- the present invention also provides a method for the preparation of a construction element comprising: a) mixing cellulose particulate material, cementitious material and cellulose ether to form a dry mixture; b) adding, with mixing to the dry mixture, water and optionally a setting agent to form a wetted cementitious composition; and c) allowing the wetted cementitious composition to harden to form the construction element.
- a method for the preparation of a construction element comprising: a) mixing a cementitious material, cellulose ether, water and optionally a setting agent to form a wetted mixture; b) adding, with mixing to the wetted mixture, cellulose particulate material to form a wetted cementitious composition; and c) allowing the wetted cementitious composition to harden to form the construction element.
- composition of the wetted cementitious compositions of the present invention may be varied depending on whether the wetted composition is allowed to set in a mould, or whether it is pressed into bricks by a block-making machine or clay-extruder machine and cut prior to being allowed to set.
- the invention also relates to lightweight construction elements such as panels and blocks when made with the cementitious compositions of the present invention.
- a lightweight construction element which simulates the appearance of granite, wherein said element is prepared from a settable mixture of:
- the construction elements prepared from the cementitious compositions of the present invention are lightweight compared to standard cement and concrete building elements which makes the elements easier to lift, carry and place when used in construction.
- the lightweight construction elements are strong and durable and are able to be cut with a normal wood saw and drilled with standard wood drill bits.
- the construction elements can hold nails or screws as does timber without the need for plugs.
- the construction elements show no appreciable crumbling or separation of the filler material when cut or drilled with standard carpentry tools.
- the cellulose particulate material is preferably sawdust.
- the sawdust is preferably fresh and is used without having first been dried, heated or kilned. It will be understood that the exact proportions of sawdust used in forming the construction elements vary according to the type of product desired.
- the present inventor has found that, in general, dry sawdust is not particularly preferred for use in the compositions of the invention due to the high amount of water required to re-hydrate the dry sawdust when preparing the compositions. Such high water content compositions give poor compaction, are slow to set and once set are more susceptible to powder or crumble when worked with standard ca ⁇ entry tools.
- the use of fresh sawdust aids in the compression of the cementitious compositions and structural strength of the elements formed therefrom. Panels and bricks so constructed are lightweight and also have very good thermal and acoustical insulating qualities.
- the sawdust derives from depends on the method by which the construction elements are formed. Hardwoods such as eucalyptus and oak are preferred for construction elements prepared by block-making machines and extrusion processes. Hardwood sawdust provides good acoustic insulation properties. Preferably, the hardwood sawdust is very fine, being similar to powder.
- soft woods such as pine are preferred when wet cementitious compositions are set in casts or moulds.
- the soft wood sawdust is preferably coarse in pieces of about 2-3 mm.
- the cellulose particulate material when used with clay-extrusion and block-compression moulding techniques is preferably present in an amount from about 30-60 wt%, more preferably 40-50 wt%, based on the total weight of the dry formulation.
- the cellulose particulate material is preferably present in an amount from about 20-70 wt%, more preferably 30-55 wt%, even more preferably 40-55 wt%.
- the particulate material may be part substituted with elastomeric beads such as, preferably, polystyrene beads.
- the beads are desirably smaller than 0.25 mm but can have a size up to 2 mm.
- the amount of elastomeric beads can, for example, approach 20 wt% when the cellulose particulate material is in an amount of about 40 wt%, and up to 40 wt% when the cellulose particulate material is in an amount of about 20 wt%.
- the construction elements prepared by the extrusion method it is favourable for the construction elements prepared by the extrusion method to have some of the cementitious material and/or cellulose particulate material replaced by up to 30 wt% of coated fly ash.
- the fly ash is required to be coated with silicone or glass to assist in creating high viscosity wetted cementitious compositions suitable for extrusion.
- Many types of fly ash are suitable.
- One source of fly ash results from the burning of coal in electrical generating facilities and this type of fly ash once coated may be effectively used in the present application. More preferably is naturally occurring volcanic fly ash, which is purified and ground as a white, finely divided powder.
- the fly ash once coated significantly enhances the quality of the construction elements prepared therefrom. Uncoated fly ash is not preferred as it absorbs large amounts of water from the wetted compositions.
- the wetted cementitious composition is a clay-like hard plasticine-type mixture.
- the mixture is extruded through a die and cut into desired lengths. Elements such as panels and blocks can be made by this method.
- the addition of silicone coated fly ash gives less dense yet higher strength products. Fly ash may be obtained from various sources including Harborlite of La Porte, Texas who market the product under the Trade name Micro fil Grade F-2.
- cement is used herein in its broadest sense to generally refer to a mixture of clay and limestone that hardens and fastens on setting.
- the cementitious material can be any cement but preferably is high strength cement such as Portland cement.
- High strength cement differs from normal cement in that it is a finer grind which causes it to cure more quickly and have a higher strength when set.
- high strength cement is not used it is preferable to add a substantially equal quantity of lime to the cement.
- the cementitious material is preferably present in an amount from about 40-60 wt% based on the total weight of the dry composition.
- the cementitious material is preferably present in an amount of from about 40-60 wt% based on the total weight of the dry formulation.
- Cellulose ethers suitable for the present invention include sodium carboxymethyl cellulose, sodium carboxymethyl hydroxyethyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl methyl cellulose, hydroxyethyl ethyl cellulose, methyl cellulose, methyl ethyl cellulose, hydroxyethyl cellulose and hydroxypropyl cellulose.
- An example of suitable cellulose ethers are those sold under the trade name Methocel available from the Dow Chemical Company which are hydroxypropyl methyl celluloses.
- the cellulose ether is Methocel 228 (available from the Dow Chemical Company) which is a partially surface treated hydroxypropyl methyl cellulose having a nominal viscosity of 4,000 cps (2% solution at 20°C), and a gel temperature of 65°C.
- the cellulose ether functions as a glue and results in more even distribution of the particulate material in the final product.
- the cellulose ether is preferably present in the amount from 0.3-0.45 wt% based on the total weight of the dry formulation.
- a setting agent is optional but aids in setting the wet cementitious compositions. Any suitable setting agent may be contemplated.
- calcium chloride is used and if present, can be present in an amount up to 2.5 wt% more preferably in the range 0.5-2 wt%, more preferably about 0.7 wt%, based on the weight of the dry formulation.
- Water should be clean and preferably be used at a temperature in the range from 10-25°C for good results.
- the amount of water required to be added to the cementitious compositions depends on the method used to form the elements.
- the cementitious compositions used in casting are thick slurries
- the compositions used in the extrusion method are semi-dry similar to clay whilst the compositions used in the block-making machine are dry-compactable or slightly damp mixtures having a low water content. Therefore for consistency throughout the description and claims, the cementitious compositions to which water has been added are referred to as "wetted" cementitious compositions irregardless of whether the compositions are subsequently cast, extruded or compacted in the preparation of the construction elements.
- the actual amount of water required in preparing the wetted compositions of the invention is dependent on the freshness and inherent moisture content of the sawdust used and can readily be determined by those skilled in the art. It will be understood that where the moisture content of the sawdust is low, more water will be required to be added. When the moisture content is high, less water will be required.
- the cementitious compositions used in the block-making machine most preferably have a small moisture content. Most of the moisture is derived from the fresh sawdust and its natural moisture content. Typically the amount of water added in preparing the wetted composition for use in the block-making machine is from 50-100 L per cubic metre of total mixture. More water is required in preparing the wetted compositions for use in the clay- extrusion method and even more water is required in preparing the wetted compositions when casting in moulds.
- Construction elements produced from the compositions of the invention can be made with various dyes and pigments if a coloured product is desired.
- the product can also be plastered, painted, sealed or rendered if required.
- sand such as river sand of preferably up to 20 wt%, more preferably from 10-20 wt%. Whilst the addition of river sand makes a heavier and more dense product, it gives better compaction and hence better products when made by a block-making machine or clay-extrusion method.
- the density of the set cementitious compositions of the invention are typically in the range of 450-800 kg/m 2 , and often from 500-700 kg/m 2 however, it will be understood that depending on the particular qualities desired by the set cementitious compositions and construction elements of the present invention, different densities may be desired. This is often achieved typically by varying the ratio of cellulose particulate material to cement in the cementitious compositions.
- Extruded construction elements of the present invention are generally suitable as load- bearing products. Construction elements made by block or casting techniques are generally not suitable for load bearing applications and are often used for making block or paneled walls.
- the polymer resins used in the granite-like construction elements are preferably a clear casting resin which are set by a curing agent.
- the polymer resins are preferably an acrylate or ester-type resin which are commonly available and well known to those skilled in the art.
- Preferably the amount of polymer resin is about 33 % by volume.
- the resin hardener is any curing agent which is able to cause the polymer resin to set.
- the resin hardener is a peroxide such as, for example, methyl ethyl ketone peroxide (MEKP) and is present in about 1 % by volume.
- MEKP methyl ethyl ketone peroxide
- the vermiculite used in the granite-like elements of the present invention are any of the micaceous minerals formed by alteration of common micas.
- Mica is comprised of hydrous 10 disilicates of aluminium with metal oxides of magnesium and iron.
- Vermiculite ore is mined in simple open cut operations usually involving grinding and air separation to delaminate the ore particles and to remove waste rock.
- the raw vermiculite ore is produced in particle sizes typically from 16 mm down to 0.25 mm, with bulk densities
- the raw vermiculite is in the form of thin sheets which form slivers and their uses within the finished material gives a flecked type appearance to the material.
- the size of the raw vermiculite slivers can be chosen depending on the desired visual effect required.
- the amount of raw vermiculite in the granite-like construction elements of the present invention are preferably 22-44 % by volume, more preferably about
- Expanded vermiculite is obtained by an exfoliating process whereby vermiculite is fed through a furnace at about 1 ,000°C producing concertina shaped granules with a loose bulk density in the range 60-160 kg/m 3 .
- Exfoliated vermiculite is advantageously used in the
- Expanded vermiculite is typically obtained from Australian and South African sources.
- the South African supply of vermiculite is preferred for use in the construction elements of the present invention however most sources of expanded vermiculite are acceptable.
- the particle size range varies from 0.5-2.0 mm up to 2.0-6.0 mm, whilst the bulk density of the exfoliated vermiculite is typically from 85 kg/m down to 70 kg/m respectively.
- the amount of expanded vermiculite used in the granite-like construction elements is in the amount from 22-44 % by volume, more preferably about 33 % by volume.
- the preferred ratio of raw vermiculite to expanded vermiculite is typically about 3 : 1 by wt%.
- the raw vermiculite and expanded vermiculite form about 60 wt% of the composition with the resin forming about 40 wt%.
- the raw vermiculite and expanded vermiculite are homogeneously mixed with a settable resin and resin hardener to form a composition which can be cast into any desired shape or extruded as required.
- the mixture is shaped into blocks, bricks or panels.
- the mixture is set in the time range of 5 minutes to 2 hours. The setting time depends on the settable resin and curing agents chosen and is also dependent on the amount of curing agent present and the temperature of the mixture.
- the granite-like construction elements produced by this method can be modified to give different colours and appearances by changing the proportions or types of raw vermiculite or expanded vermiculite used. It is also possible to add various dyes and pigments if a different coloured product is desired.
- the dry ingredients are placed in a mixer, preferably in the order listed above.
- the ingredients are mixed by rotation after which water is added until the desired consistency is obtained. It will be understood that other methods of addition and mixing would also be suitable, such as for example, mixing cementitious material, cellulose ether, water and optionally a setting agent to form a wet mixture and adding cellulose particulate material with mixing to the wet mixture to form a wetted cementitious composition.
- the wetted cementitious composition so formed is placed in a block-making machine, clay- extrusion machine or a form depending on the particular ratio of ingredients used and the desired properties of the construction element so produced once set.
- the wetted cementitious compositions formed in casts may be removed after 8 hours under normal conditions and should be left for up to 14 days to cure prior to use in construction.
- Construction elements formed by block-making techniques or the extrusion method are set in 5-20 minutes and should also be left for up to 14 days to cure prior to use.
- the raw vermiculite and expanded vermiculite are homogeneously mixed with the settable resin and resin hardener to form a composition which is cast into any desired shape or extruded as required.
- the mixture sets within 2 hours.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- Combustion & Propulsion (AREA)
- Civil Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ509549A NZ509549A (en) | 1998-07-10 | 1998-06-30 | A lightweight cement composition containing cellulose particles that is used as a construction element |
AU47622/99A AU753855C (en) | 1998-07-10 | 1999-07-09 | Construction element |
GB0102740A GB2363118A (en) | 1998-07-10 | 1999-07-09 | Construction element |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPP4613A AUPP461398A0 (en) | 1998-07-10 | 1998-07-10 | Cementitious composition |
AUPP4613 | 1998-07-10 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000002826A1 true WO2000002826A1 (en) | 2000-01-20 |
Family
ID=3808851
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU1999/000555 WO2000002826A1 (en) | 1998-07-10 | 1999-07-09 | Construction element |
Country Status (5)
Country | Link |
---|---|
AU (1) | AUPP461398A0 (en) |
GB (1) | GB2363118A (en) |
MY (1) | MY140558A (en) |
NZ (1) | NZ509549A (en) |
WO (1) | WO2000002826A1 (en) |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2001085639A1 (en) * | 2000-05-05 | 2001-11-15 | Peter Collier | Improvements in building blocks |
WO2006037187A1 (en) * | 2004-10-08 | 2006-04-13 | E.I.F.S. Holdings Limited | Improved cementitious mixtures |
ES2311384A1 (en) * | 2006-11-29 | 2009-02-01 | Ibercal Morteros, S.L. | Ecological and insulating coating for the construction and process for its obtaining (Machine-translation by Google Translate, not legally binding) |
ES2315189A1 (en) * | 2006-08-24 | 2009-03-16 | Sergio Fregonese | Cement composition of insulating materials of different classes (Machine-translation by Google Translate, not legally binding) |
DE202007018759U1 (en) | 2006-03-22 | 2009-04-16 | Kruss, Leon, Waverley | building materials |
US7632348B2 (en) | 2005-03-22 | 2009-12-15 | Nova Chemicals Inc. | Lightweight concrete compositions containing antimicrobial agents |
US7644548B2 (en) | 2005-03-22 | 2010-01-12 | Nova Chemicals Inc. | Lightweight concrete compositions |
US7648574B2 (en) | 2005-03-22 | 2010-01-19 | Nova Chemicals Inc. | Lightweight concrete compositions |
AU2010201365B2 (en) * | 2000-05-05 | 2012-01-19 | Peter Collier | Improvements in Building Blocks |
AU2007229318B2 (en) * | 2006-03-22 | 2012-10-04 | Leon Kruss | Construction product |
US8357240B2 (en) | 2005-03-22 | 2013-01-22 | Syntheon Inc. | Method of making concrete |
WO2013117929A1 (en) * | 2012-02-07 | 2013-08-15 | Econovate Ltd. | A building method to produce lightweight building blocks from cellulose fibre |
CN108975785A (en) * | 2018-08-27 | 2018-12-11 | 盐城市荣立新型建材有限公司 | The cement process for producing bricks of natural-like stone |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5047086A (en) * | 1988-05-06 | 1991-09-10 | Shin-Etsu Chemical Co., Ltd. | Cement composition for extrusion |
DE4218143C1 (en) * | 1992-06-02 | 1993-07-15 | Deutsche Perlite Gmbh, 4600 Dortmund, De | |
US5482550A (en) * | 1991-12-27 | 1996-01-09 | Strait; Mark C. | Structural building unit and method of making the same |
WO1998037032A1 (en) * | 1997-02-18 | 1998-08-27 | Windsor Technologies Limited | Method of treating a lignocellulosic material or an expanded mineral to form a finished product |
-
1998
- 1998-06-30 NZ NZ509549A patent/NZ509549A/en not_active IP Right Cessation
- 1998-07-10 AU AUPP4613A patent/AUPP461398A0/en not_active Abandoned
-
1999
- 1999-07-09 GB GB0102740A patent/GB2363118A/en not_active Withdrawn
- 1999-07-09 WO PCT/AU1999/000555 patent/WO2000002826A1/en active IP Right Grant
- 1999-07-09 MY MYPI9902910 patent/MY140558A/en unknown
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5047086A (en) * | 1988-05-06 | 1991-09-10 | Shin-Etsu Chemical Co., Ltd. | Cement composition for extrusion |
US5482550A (en) * | 1991-12-27 | 1996-01-09 | Strait; Mark C. | Structural building unit and method of making the same |
DE4218143C1 (en) * | 1992-06-02 | 1993-07-15 | Deutsche Perlite Gmbh, 4600 Dortmund, De | |
WO1998037032A1 (en) * | 1997-02-18 | 1998-08-27 | Windsor Technologies Limited | Method of treating a lignocellulosic material or an expanded mineral to form a finished product |
Cited By (22)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2001085639A1 (en) * | 2000-05-05 | 2001-11-15 | Peter Collier | Improvements in building blocks |
AU2010201365B2 (en) * | 2000-05-05 | 2012-01-19 | Peter Collier | Improvements in Building Blocks |
EP1817267A4 (en) * | 2004-10-08 | 2011-08-17 | E I F S Holdings Ltd | Improved cementitious mixtures |
WO2006037187A1 (en) * | 2004-10-08 | 2006-04-13 | E.I.F.S. Holdings Limited | Improved cementitious mixtures |
EP1817267A1 (en) * | 2004-10-08 | 2007-08-15 | E.I.F.S. Holdings Limited | Improved cementitious mixtures |
USRE43253E1 (en) | 2005-03-22 | 2012-03-20 | Nova Chemicals Inc. | Lightweight concrete compositions |
US8357240B2 (en) | 2005-03-22 | 2013-01-22 | Syntheon Inc. | Method of making concrete |
US7644548B2 (en) | 2005-03-22 | 2010-01-12 | Nova Chemicals Inc. | Lightweight concrete compositions |
US7648574B2 (en) | 2005-03-22 | 2010-01-19 | Nova Chemicals Inc. | Lightweight concrete compositions |
US7658797B2 (en) | 2005-03-22 | 2010-02-09 | Nova Chemicals Inc. | Lightweight concrete compositions |
US7744692B2 (en) | 2005-03-22 | 2010-06-29 | Nova Chemicals, Inc. | Lightweight concrete compositions |
US7820094B2 (en) | 2005-03-22 | 2010-10-26 | Nova Chemicals Inc. | Lightweight concrete compositions |
US7632348B2 (en) | 2005-03-22 | 2009-12-15 | Nova Chemicals Inc. | Lightweight concrete compositions containing antimicrobial agents |
US8029617B2 (en) | 2005-03-22 | 2011-10-04 | Nova Chemicals Inc. | Lightweight concrete compositions |
US8167998B2 (en) | 2005-03-22 | 2012-05-01 | Nova Chemicals Inc. | Lightweight concrete compositions |
AU2007229318B2 (en) * | 2006-03-22 | 2012-10-04 | Leon Kruss | Construction product |
DE202007018759U1 (en) | 2006-03-22 | 2009-04-16 | Kruss, Leon, Waverley | building materials |
ES2315189A1 (en) * | 2006-08-24 | 2009-03-16 | Sergio Fregonese | Cement composition of insulating materials of different classes (Machine-translation by Google Translate, not legally binding) |
ES2311384A1 (en) * | 2006-11-29 | 2009-02-01 | Ibercal Morteros, S.L. | Ecological and insulating coating for the construction and process for its obtaining (Machine-translation by Google Translate, not legally binding) |
WO2013117929A1 (en) * | 2012-02-07 | 2013-08-15 | Econovate Ltd. | A building method to produce lightweight building blocks from cellulose fibre |
US9724853B2 (en) | 2012-02-07 | 2017-08-08 | Econovate Ltd. | Building method to produce lightweight building blocks from cellulose fibre |
CN108975785A (en) * | 2018-08-27 | 2018-12-11 | 盐城市荣立新型建材有限公司 | The cement process for producing bricks of natural-like stone |
Also Published As
Publication number | Publication date |
---|---|
AUPP461398A0 (en) | 1998-08-06 |
GB2363118A (en) | 2001-12-12 |
GB0102740D0 (en) | 2001-03-21 |
MY140558A (en) | 2009-12-31 |
NZ509549A (en) | 2004-04-30 |
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