WO2005018896A1 - Procede de production de materiaux a base de ciment et d'asphalte a renfort de fibres - Google Patents

Procede de production de materiaux a base de ciment et d'asphalte a renfort de fibres Download PDF

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Publication number
WO2005018896A1
WO2005018896A1 PCT/US2003/028027 US0328027W WO2005018896A1 WO 2005018896 A1 WO2005018896 A1 WO 2005018896A1 US 0328027 W US0328027 W US 0328027W WO 2005018896 A1 WO2005018896 A1 WO 2005018896A1
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WO
WIPO (PCT)
Prior art keywords
aggregate
mixture
fiber
dispensing
providing
Prior art date
Application number
PCT/US2003/028027
Other languages
English (en)
Inventor
Paul E. Bracegirdle
Original Assignee
Bracegirdle P E
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
Priority claimed from US10/641,410 external-priority patent/US6971784B1/en
Application filed by Bracegirdle P E filed Critical Bracegirdle P E
Priority to AU2003270385A priority Critical patent/AU2003270385A1/en
Publication of WO2005018896A1 publication Critical patent/WO2005018896A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C11/00—Details of pavings
    • E01C11/16—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/40—Mixing specially adapted for preparing mixtures containing fibres
    • B28C5/404—Pre-treatment of fibres
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C19/00—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving
    • E01C19/02—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for preparing the materials
    • E01C19/10—Apparatus or plants for premixing or precoating aggregate or fillers with non-hydraulic binders, e.g. with bitumen, with resins, i.e. producing mixtures or coating aggregates otherwise than by penetrating or surface dressing; Apparatus for premixing non-hydraulic mixtures prior to placing or for reconditioning salvaged non-hydraulic compositions
    • E01C19/1059—Controlling the operations; Devices solely for supplying or proportioning the ingredients
    • E01C19/1068—Supplying or proportioning the ingredients

Definitions

  • This invention relates to and teaches processes for making aggregate-containing hot-mix asphalt and cementitous structural materials that have reinforcing fibers extracted from fiber pellets formed from waste carpet materials or textiles substantially uniformly distributed throughout.
  • the present invention sets forth processes for employing the fibers embedded within the waste carpet pellets or textile pellets as a fiber source for • improving the static and dynamic physical properties of structural entities such as asphalt and concrete roadbeds and concrete beams and piers and other concrete structural elements . Important economic benefits arise from improvements in the static and dynamic physical properties of road construction and surfacing materials-.
  • the carpet reclaiming process yields a fluffy, curly fiber that is difficult to handle, and difficult to dispense reliably and accurately. Further, the loose fibers are easily inhaled and such inhalation by workers may have serious health and therefore economic implications . Because the cost of forming the pellets is substantially offset by the abrogated cost of disposing of the carpet or textile in landfills, the reclaimed carpet Nylon fibers in pellet form are relatively low cost. Also, the tubular Nylon carpet pellets flow freely through typical hoppers compared with the fluffy, curly virgin or the ⁇ ginned' fibers reclaimed from the carpets . Fiber binders have been known to have been used in thermally or chemically hardening materials to improve their strength, flexibility and resistance to cracking.
  • a multi-step process for providing with fiber reinforcement congealable materials that include aggregate such as hot liquid asphalt or Portland cement concrete includes the steps of: providing a source of aggregate material and a source of fiber that is primarily derived from waste carpeting or waste textiles; providing a source of congealable material; providing means such as a rotary drum for mixing materials, then dispensing a quantity of aggregate material and fiber into the mixer and mixing them before any liquid or congealable material is added. The dry mixing of the fiber and aggregate disperses the fiber and breaks up fiber clumps. Finally the congealable material is added to the mixer and mixed with the aggregate and fiber causing the fiber and aggregate to be distributed uniformly through the mix.
  • ASPHALT CURRENT USAGE A typical road employing hot-mix asphalt has about 93% aggregate of stones, sand and recycled waste materials. Typically six percent (6%) by weight of the final mixture is the liquid asphalt binder. Where fibers are required, polyester is used at the rate of 6 pounds fiber per ton of total mix or 5% by weight of the liquid asphalt.
  • the fiber pellets formed from waste carpet typically have a cylindrical shape and are about 0.25 inches in diameter and 0.25 to 0.5 inches long. Analysis of the fibers within the pellets shows the fiber length as 4.8mm +/- 2.7mm. A sample of this pelletized carpet weighs in the range of 16-26 lb/cu.ft.
  • Nylon fiber-45% polypropylene 10% styrene-butadiene polymer 9% and calcium carbonate 36%.
  • the polypropylene acts as the binder or the fibers .
  • Polypropylene melts at about 32OF while the Nylon melts in the range of 530 - 540F.
  • Polyester fiber is supplied in bags as a loose, fluffy bulk material. It is difficult to precisely meter or feed such loose fiber into a process or a metered asphalt flowstream. Therefore it is common to pre-mix the fiber in the liquid asphalt in vats or tanks that are equipped with costly integral motor driven mixers . Further, in this process there is no certainty of the uniform distribution of the fibers throughout the liquid asphalt in the vat.
  • Typical fiber concentrations that have been successfully employed in fiber reinforced concretes range from 20 to 30 pounds fiber per cubic yard finished concrete.
  • Polyester or polyolefin fibers have been applied at the rate of 10-20 pounds fiber per cubic yard (pcy) of total mix. Not only have these fibers been costly, they have been applied as a loose fluffy material that is difficult to meter or feed precisely into a process. Since the loose fiber is difficult to handle, to meter or feed, it is premixed with the cement powder or simply mixed into the final product. This process causes haphazard distribution of fiber throughout the batch. Applying fibers to the cement powder requires the hopper to have an integral mixer which is costly to secure and awkward to operate. Further, since loose fibers have a tendency to clump, uniform feeding of the loose fibers and uniform distribution of the fibers through the cement powder or the final product has been uncertain.
  • FIG. 1 illustrate fiber sources and means for dispensing them. Since all the processes require mixing the second mixture before it is applied to the application, the description of some of the processes omit this detail.
  • Figures 1, 2 and 3 display the sources of the various materials such as aggregate 20, fiber 26 and hot asphalt 80.
  • the numbers of the outlet conduits for each such as aggregate 22, fine aggregate 70 and hot asphalt 82 are employed to designate both the dispensing step and the related source.
  • Figure 1 shows rudimentary views of source, dispensing, mixing and heating components employed in the processes of the invention.
  • Figure 2 illustrates components for receiving, heating, separating and dispensing fine and coarse materials.
  • Figures 5 through 14 are timelines showing visually the analog characterizations of the times for the material input from the sources, the mixing, heating and dispensing.
  • cement powder employed herein is intended to apply to powders or slurries of powders that, when mixed with water, harden to a useful degree. These powders could be limestone cement, coal ash or a mixture of these or none of these with or without other ingredients that are deemed economically or mechanically useful in the mix.
  • the process for producing aggregates almost always produces a mixture of coarse and fine aggregates. It is intended that fine aggregates may include sand or other fine materials. It is not otherwise the intention of this specification to specify the dividing size between fine and coarse aggregates or to specify their relative proportions in the concrete mix since these ratios depend on the applications .
  • pelletized carpet fibers or carpet pellets or some other reference to pellets must be understood to always include a percentage of loose or fluffy fibers .
  • ⁇ fibers' is intended to refer to these. This specification is not intended to provide specific formulae or ingredient ratios.
  • ⁇ cement' or ⁇ cement powder' is intended to refer to cement powder including Portland Cement powder or cementitious powders from other sources.
  • the term 'source' is intended to be any stock of material.
  • a source may be in the form of a mound or pile or in the form of material held in a container or vessel or railcar or truck.
  • Figures 1, 2 and 3 display the sources of the various materials such as aggregate 20, fiber 26 and hot asphalt 80.
  • the numbers of the outlet conduits for each such as aggregate 22, fine aggregate 70 and hot asphalt 82 are sometimes employed to designate both the dispensing step and the related source.
  • ⁇ dispense' is intended to refer to delivery of material to the process in any manner.
  • conduit' as employed herein is intended to refer to any means of transferring material from one place to another.
  • a metering or flow control device or process step is intended to refer to and include any means of controlling, measuring or estimating the amount transferred.
  • Such a device may be a flow control valve or a measured volume, including, for instance, the vo.lume of a bucket of a back hoe or a bin gate.
  • a congealable material is any material that is initially flowable or mixable including powders and liquids, that hardens after a time or after mixing with water or after exposure to a process such as heating, cooling or exposure to ultra violet radiation.
  • a preferred embodiment of the invention is described as follows with reference to figure 1.
  • Aggregates such as crushed rock, crushed concrete, cinders etc. are stored in source 20 and metered via device 24 through conduit 22 to mixer 38.
  • Fiber pellets are dispensed at the rate of 40 to 60 pounds pellets per cubic yard of final (second) mix, from source 26 through metering device 30 through conduit 28 to mixer 38 thereby forming a first mixture.
  • the sources of fiber from which the pellets are produced are either waste carpeting 18 or waste textile 19 or a mixture of them.
  • the mixer is caused to operate for a time period (see figure 5 for example) in the range of 30 seconds to 5 minutes.
  • the duration of the time period depends on the fiber content of the pellets, typically 40 to 50 percent fiber, and the binding characteristic of the pellets, the speed of the mixer and the size range of the aggregates. It would be expected that a user would sample this first mixture after a mixing period to determine the approximate fraction of the pellets that had been disrupted into the form of individual fibers and to extend the period if a higher fiber yield was required in order to provide the desired fiber concentration, typically 20 to 40 pounds of fiber per cubic yard of final mix. After a mixing time during which the pellets in the first mixture have been sufficiently abraded to release the desired concentration of loose fiber, congealable material from source 32 is dispensed via metering device 36 and conduit 34 into mixer 38 to form the second mixture.
  • mixer 38 is a long rotating heatable kiln that is pitched in the direction of flow.
  • Aggregate 20 is continuously metered into the entering or high end of the kiln along with a continuous metered flow of fiber pellets 26 or 26A, thereby forming a first mixture.
  • the first mixture moves in a stream to a midpoint in the rotating kiln where a congealable material such as ot asphalt 82 is added via control 84 and conduit 82, thereby forming a second mixture.
  • the stream comprising the second mixture continues moving toward the low end of the kiln while the mixing of the congealable material and the ingredients of the first mixture are thoroughly performed. At the low end of the kiln the thoroughly mixed second mixture is continuously discharged 40 to storage or the application. The continuous process continues until the dispensing of the ingredients in discontinued.
  • the first- mixture described in the first embodiment is mixed with congealable material in the form of cementitious powder and water.
  • the cementitous powder hereafter characterized as cement or cement powder, is fed from hopper 90 into the mixer 38 via control 94 and conduit 92 and water is fed from hopper 96 substantially simultaneously with the cement powder into mixer 38 via' control 100 and through conduit 98, thereby forming a second mixture.
  • the second mixture is mixed for a sufficient time to secure the desired mixing of the constituents and then the second mixture is dispensed to transportation or storage means or directly to the point of application for road bed or structural components .
  • the aggregate from 20 is dispensed via conduit 22 to mixer 38 substantially simultaneously with fiber from source 26 dispensed via conduit 28 and the cement powder from source 90 via conduit 92 and metered by element 94 thereby forming a first mixture.
  • the first mixture is then mixed in mixer 38 for a time period during which the fiber pellets are disrupted into their fiber and other constituents and the cement is distributed throughout the first mixture.
  • FIG 2 there is shown a source of mixed aggregate 60.
  • the mixed aggregate contained in source 60 has both coarse and fine components or particles.
  • a heater 61 is provided whereby the contents of source 60 may be heated either directly or indirectly. Where heating has occurred the source is designated by H as 62H for heated mixed aggregate, 7OH for heated fine aggregate and 72H for heated coarse aggregate.
  • the mixed aggregate in source 60 is fed through control 64 into screening device 66 via conduit 62.
  • the screening device 66 has positioned therein screen 58 having openings that pass the desired range of small sizes and retain, or fail to pass, larger aggregate particles.
  • coarse aggregate particles are dispensed through flow control 74, via conduit 72 into the process.
  • fine aggregate is dispensed via conduit 70, through flow control 71 into the process.
  • the mixed aggregate 62 is dispensed directly into mixer 38 with fiber 28 or 28C to form the first mixture.
  • only coarse aggregate is dispensed from source 60 through the screening mechanism 66 and control 74 and conduit 72 to mixer 38.
  • Fiber pellets from source 26 are dispensed through control 30 in the required amount via conduit 28 to mixer 38, thereby forming the first mixture.
  • Other dry ingredients may also be added such as cement powder, fine aggregate or other dry materials as described in connection with the prior embodiments .
  • congealable material is added.
  • the congealable material may be selected from the group comprising hot or cold liquid asphalt, water only or cement and water, thereby forming a second mixture.
  • the second mixture is dispensed to the application.
  • the fluffy fibers may have as their source waste carpet, waste textiles or non- waste materials including stainless steel fibers or fibers from natural sources such as cotton, wool, jute or hemp.
  • the flows and therefore the proportions of the pellets and the fluffy fibers are regulated by flow controls 30A and 30B, respectively and are dispensed via outlet conduits 28A and 28B into combined outlet conduit 26C.
  • FIG 4 there is displayed a shorthand representation of one manifestation of the process where aggregate 22 and fiber 28 are dispensed substantially simultaneously into mixer 38 (not shown in the short-hand figures) .
  • the initial dry materials _ comprising the first mixture are mixed for time period A at the conclusion of which congealable material 34 is added to form the second mixture.
  • the second mixture is mixed for time period B, at the conclusion of which the second mixture is dispensed via conduit 40 to the application.
  • the congealable material is hot or cold liquid asphalt 82 that is mixed into the first mixture of aggregate 22 and fiber 28 after mixing period A.
  • Figure 8 shows that hot coarse aggregate 72H and fiber pellets 28C form the first mixture and that, after mixing, hot fine aggregate 70H and hot asphalt liquid 82 are added to form the second mixture.
  • figure 9 there is shown the process where a mixture of coarse and fine aggregates 62 plus pellets 28C form the first mixture and that heater 39 is energized acting on the materials being mixed in mixer 38 and heating them during the mixing process. Hot asphalt 82 is added to form the second mixture. The action of heater 39 may be continued during mixing period B if desired.
  • Figure 10 teaches that aggregate 22 plus fiber 28 are dispensed to form the first mixture and that cementitous material 92 including but not limited to Portland cement powder and water are added to form the second mixture after the initial mixing period A.
  • FIG 11 the process is shown where aggregate 22 and pellets 28C, possibly but not necessarily having some fluffy fiber, are mixed, forming the first mixture. Cement 92 and water 98 are added to the first mixture after the mixing period A to form the second mixture.
  • a mixture of coarse and fine aggregates 62 and fiber pellets 28C form the first mixture and cement 92 and water 98 are subsequently added to form the second mixture.
  • Figure 13 displays the first mixture comprising coarse aggregate 72 and fiber 28. The second mixture is formed when the fine aggregate 70, cement 92 and water 98 are added.
  • Figures 1 and 3 illustrate the process for producing asphalt concrete having both aggregate and fiber produced from fiber pellets whose fiber source is either or both waste carpeting or waste textile.
  • the pellets 28A or 28 and the aggregate 22 are delivered to mixer 38 thereby forming the first mixture.
  • the first mixture is then mixed by mixer 38 for a time period A sufficient for a substantial portion of the fibers in the pellets to have been abraded away from the pellets and for such fibers to be distributed throughout the first mixture.
  • hot liquid asphalt 82 is added to the first mixture, thereby forming the second mixture.
  • the second mixture is mixed in mixer 38 or in another mixer not shown for time period B sufficient for the hot asphalt to be distributed throughout the second mixture and to coat the aggregate 22 and the fiber resulting from the disruption of pellets 28 or 28A.
  • the resulting mix is then dispensed to storage or directly to the application.
  • the mixer initially operates dry, with the various ' aggregate compositions and the pellets but without the addition of any liquid.
  • the mixer acts to grind the pellets with the coarse aggregate while simultaneously mixing the freed fibers released from the pellets into the dry batch.
  • a brief mixing period typically 30 seconds to 10 minutes, during which the dry mixer operates to thoroughly disrupt the pellets into their constituent fibers and mix the fibers through the aggregate and cement powder
  • water is introduced in the required measured amount via control 100.
  • the Portland cement concrete mix is ready to apply to or transport to the application.
  • the grinding and mixing action of the mixer or mixer drum 38 on the aggregate, cement powder and pellet mixture causes the pellets to become completely disrupted and the fibers blended with the aggregate and cement powder.
  • the Nylon fibers having been disrupted from the pellets by the grinding action of the aggregate, are thereby uniformly distributed throughout the entire Portland cement concrete mix which is then delivered to the road or application via conduit 40 as final Portland cement concrete.
  • I teach the use of the raw bulk fiber, either as manufactured by 3M or as separated by ginning from the waste carpet, instead of pellets, in each of the processes, prior to addition of water or other congealable material. From the foregoing description, it can be seen that the present invention comprises an unusual and unobvious method for minimizing the deposition of waste carpets and waste textiles in land fills and simultaneously improving the quality of structural material.

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Processing Of Solid Wastes (AREA)
  • Road Paving Structures (AREA)

Abstract

La présente invention a trait à un procédé permettant la rupture mécanique efficace de granulats de fibres (26) dérivés de matériau de tapis usés (18) en brins individuels en vue de l'incorporation et de la distribution uniforme de telles fibres à travers des matériaux congelables tels que l'asphalte (80) et le béton (90), procurant ainsi des propriétés physiques améliorées aux solides obtenus, et assurant une utilisation pour de tels matériaux de tapis usés (18), minimisant ainsi leur dépôt dans des lieux d'enfouissement.
PCT/US2003/028027 2003-08-15 2003-09-08 Procede de production de materiaux a base de ciment et d'asphalte a renfort de fibres WO2005018896A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003270385A AU2003270385A1 (en) 2003-08-15 2003-09-08 Process for producing fiber reinforced asphaltic and cementitious materials

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/641,410 2003-08-15
US10/641,410 US6971784B1 (en) 2002-09-06 2003-08-15 Process for producing fiber reinforced hot-mix asphaltic and cementitous structural materials with fiber pellets produced from carpet waste

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WO2005018896A1 true WO2005018896A1 (fr) 2005-03-03

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113998943A (zh) * 2021-11-25 2022-02-01 杨洋 一种保温型再生混凝土

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4662759A (en) * 1985-12-19 1987-05-05 Hercules Incorporated Premix injection system for asphalt compositions
US4716893A (en) * 1985-03-11 1988-01-05 Artur Fischer Bone fastener
US4887908A (en) * 1988-03-23 1989-12-19 Montgomery Darryl R Mobile asphalt crack sealant apparatus
US4955721A (en) * 1987-09-28 1990-09-11 Clark Lloyd T Apparatus for applying a sulphur-based structural material to paved surfaces
DE3927252A1 (de) * 1989-08-18 1991-02-21 Eirich Maschf Gustav Verfahren zur herstellung faserstoffhaltiger baustoffmischungen
EP0499572A1 (fr) * 1991-02-12 1992-08-19 Skako A/S Procédé et installation pour la coupe du fil continu en fibres coupées et dosant les dernières dans un mélange béton
EP0509893A1 (fr) * 1991-04-18 1992-10-21 Isover Saint-Gobain Procédé et dispositif de préparation d'enrobé bitumineux
FR2682308A1 (fr) * 1991-10-14 1993-04-16 Screg Routes & Travaux Procede et poste d'enrobage d'agregats avec du bitume et des fibres, notamment des fibres de verre, et dispositif d'incorporation d'un produit particulaire dans du bitume.
DE4244559A1 (de) * 1992-12-30 1994-07-07 Bituminosos S A Probisa Pinto Verfahren und Vorrichtung für die Verteilung und Dosierung von im Bausektor im allgemeinen verwendeten Fasern
WO1995009723A1 (fr) * 1993-10-05 1995-04-13 Confiber Ab Procede d'adjonction de fibres de renforcement a un materiau moule et dispositif d'apport et d'adjonction de ces fibres
US5407139A (en) * 1993-03-29 1995-04-18 Interfibe Corporation Method and apparatus for dispersing and metering fibers

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4716893A (en) * 1985-03-11 1988-01-05 Artur Fischer Bone fastener
US4662759A (en) * 1985-12-19 1987-05-05 Hercules Incorporated Premix injection system for asphalt compositions
US4955721A (en) * 1987-09-28 1990-09-11 Clark Lloyd T Apparatus for applying a sulphur-based structural material to paved surfaces
US4887908A (en) * 1988-03-23 1989-12-19 Montgomery Darryl R Mobile asphalt crack sealant apparatus
DE3927252A1 (de) * 1989-08-18 1991-02-21 Eirich Maschf Gustav Verfahren zur herstellung faserstoffhaltiger baustoffmischungen
EP0499572A1 (fr) * 1991-02-12 1992-08-19 Skako A/S Procédé et installation pour la coupe du fil continu en fibres coupées et dosant les dernières dans un mélange béton
EP0509893A1 (fr) * 1991-04-18 1992-10-21 Isover Saint-Gobain Procédé et dispositif de préparation d'enrobé bitumineux
FR2682308A1 (fr) * 1991-10-14 1993-04-16 Screg Routes & Travaux Procede et poste d'enrobage d'agregats avec du bitume et des fibres, notamment des fibres de verre, et dispositif d'incorporation d'un produit particulaire dans du bitume.
DE4244559A1 (de) * 1992-12-30 1994-07-07 Bituminosos S A Probisa Pinto Verfahren und Vorrichtung für die Verteilung und Dosierung von im Bausektor im allgemeinen verwendeten Fasern
US5407139A (en) * 1993-03-29 1995-04-18 Interfibe Corporation Method and apparatus for dispersing and metering fibers
WO1995009723A1 (fr) * 1993-10-05 1995-04-13 Confiber Ab Procede d'adjonction de fibres de renforcement a un materiau moule et dispositif d'apport et d'adjonction de ces fibres

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113998943A (zh) * 2021-11-25 2022-02-01 杨洋 一种保温型再生混凝土
CN113998943B (zh) * 2021-11-25 2022-12-27 台州银基建材有限公司 一种保温型再生混凝土

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