WO2009059568A1

WO2009059568A1 - Fireproof building material

Info

Publication number: WO2009059568A1
Application number: PCT/CZ2008/000014
Authority: WO
Inventors: Juraj Ochvat; Petr KREJCÍ
Original assignee: Juraj Ochvat; Krejci Petr
Priority date: 2007-11-08
Filing date: 2008-01-29
Publication date: 2009-05-14
Also published as: CZ18141U1

Abstract

Fireproof building material contains 5 to 20% of cement, 20 to 60% of expanded granulated filler, 20 to 60% of silicic water glass, 5 to 20% of TiO2, and 5 to 10% of substances from the group of ammonium phosphates, given as percentage by weight in the resulting mixture. Preferably ammonium dihydrogen phosphate is contained. Special-purpose admixtures such as pigments are contained in the quantity of 0.01 to 5%, if there are any.

Description

Fireproof building material

Field of the invention

The technical solution relates to the composition of a fireproof material suitable for building industry, particularly for the production of fireproof slabs and panels.

Present state of the art

Currently, various materials are used in the building industry for the fire protection, from which corresponding building elements are produced such as slabs, door panels, construction aperture fillings, etc. These materials differ in the method of production, mass, as well as fireproof and insulation properties. Common cement mixtures for building purposes contain cement in the amount up to 25% by weight and sand and/or gravel, or possibly lime. Heat- insulating cement materials contain usually also granulated polystyrene or expanded pearlite. However these mixtures show a low fire resistance and high demands on production, because these mixtures require pressing. Wastes, which have no possible secondary use for the production of further mixture, are arising during the production of cast stock or mouldings.

Fireproof materials for the building industry are often based on expandable mixtures. As an example, other material for heat, fire and sound insulations is invented in the CZ pat. No. 278 170. It is created from a mixture of water soluble cellulose derivate, aqueous dispersion of thermoplastic polymer, finely ground inorganic filling aggregate, air-entrained granulated filler with the grain size from 0.1 to 6 mm, surfactants such as wetting agents and frothing agents, and also plaster, cement and potassium water glass. This material is suitable for the production of moulded bricks for building industry. Its significant disadvantage is a demanding composition of the mixture and a production method. The material is produced by sequential mixing of components in complicated ratios, where a quite demanding process of preparation of the basic mixture is defined first, and than addition of next ingredients is allowed. Final mixing of all ingredients is followed by frothing up the mixture to a frothed condition. Complicated process and intricate contents of individual components are the disadvantages of this material. The intricacy of the composition is caused by the need to prepare separately so called basic mixture, which is then added in the amount of 4 mass parts to other components quantified as mass parts relative to the basic mixture. Therefore errors can easily appear during manufacture or during calculation of the mixture composition, which can result in qualitative material defects or formal defects in the accompanying material protocols. Due to the requirement of frothing up the material and its subsequent drying, the production is laborious and time demanding. Because of the requirements for many ingredients, some of which are financially more demanding, production of this material poses relatively high demands on the administration and organization, and it is expensive.

On the contrary, other materials are easily accessible and pose low demands on the production, but these materials such as classic concrete have very low fireproof or heat-insulation characteristics. The market and the building industry are continuously looking for other suitable materials fulfilling the demanding fire protection criteria and simultaneously having easy manufacture and the widest range of use according to the particular properties.

Essence of the invention:

The above-mentioned disadvantages are eliminated to a considerable extent by the invention hereinafter. A new mixture is invented that allows easy production, is financially and materially relatively undemanding, and is suitable for wide utilisation in building industry. The invented fireproof building material is a material based on cement and expanded granulated filler such as granulated polystyrene and/or expanded pearlite. It contains cement in the quantity of 5 to 20 percent by weight in the resulting mixture and expanded granulated filler in the quantity of 20 to 60 percent by weight in the resulting mixture. The essence of the invention of the material is that beside the ingredients mentioned above, it contains silicic water glass in the quantity of 20 to 60%, titanium dioxide in the quantity of 5 to 20%, and substances from the group of ammonium phosphates in the quantity of 5 to 10%, whereas all the percentages listed here are given as percentages by weight.

Ammonium dihydrogen phosphate is preferably used as the substance from the group of ammonium phosphates.

The material preferably contains also special-purpose admixtures in the quantity of 0.01 to 5 percent by weight in the resulting mixture, such as stabilizers against UV radiation, rapid-cementing agents, antibacterial agents etc.

Further it contains preferably pigments as admixtures. The invented material has high fireproof properties even in the A1 category. Furthermore, it also has heat-insulating properties and electric insulation properties and it has a relatively low mass. It allows easy production with simple calculation of ingredient content. The material can be processed by mere pouring, i.e. by casting into mould or by pouring onto suitable support or, as the case may be, by pouring into the cavity intended for filling in. Possible processing scrap or material debris can be secondarily processed and used in the form of chippings as a material into a new mixture of the same or similar composition. Considering the availability of ingredients on the market as well as low demands on manufacture, the material is not demanding materially and easily affordable. It is suitable for use particularly in the building industry in the form of slabs, lining, lagging, encasement, for the production of fireproof blocks and other building elements as well as for fireproof door panels and fireproof construction aperture fillings. It is suitable especially for heat-insulation and fireproof purposes.

Examples of embodiment of the invention Example 1

An example of embodiment of the invention is the grey material that has been mixed as a mixture of the following ingredients:

Substance % by weight

Silicic water glass based on sodium silicate Na₂SiO₃ 20

Expanded granulated filler: pearlite 27

Titanium white: titanium dioxide TiO₂ 20

Ammonium dihydrogen phosphate NH₄H₂PO-1 10 Cement 20

Pigment: Carbonic powder C 3

This material has been produced by mixing the ingredients listed above in a mixer and the resulting mixture was poured in the liquid state into moulds and allowed to set up. After solidification, the material was released from moulds and used after final drying as the Class A1 fireproof panels with heat- insulating properties in the building industry. When adjustment of dimensions was required, panels were cut from this material and possible scrap or debris were crushed and the resulting chippings were put into a mixer during the next production batch of the material.

Example 2

Other example of embodiment of the invention is the off-white material that has been mixed as a mixture of the following ingredients: Substance % by weight

Silicic water glass based on sodium silicate Na₂Siθ₃ 60

Expanded granulated filler: polystyrene foam balls 21,5

Titanium white: titanium dioxide TiO₂ 5 Ammonium dihydrogen phosphate NH₄H₂PO4 5

Cement 8

Pigment: carbonic powder C 0,5

This material has been produced by mixing the ingredients listed above in a mixer and the resulting mixture was poured in the liquid state into moulds and allowed to set up. After solidification, the material was released from moulds and used as the Class A1 fireproof door panels after final drying.

Example 3

Example of embodiment of the invention is the decorative fireproof material that has been mixed as an ideal mixture from the following ingredients:

Substance % by weight

Silicic water glass based on sodium silicate Na₂SiO₃ 40

Expanded granulated filler: pearlite 27

Titanium white: titanium dioxide TiO₂ 12,5

Ammonium dihydrogen phosphate NH₄H₂PO4 7 Cement 10

Pigment: paint pigment 3,5

This material has been produced by mixing the ingredients listed above in a mixer and the resulting mixture was poured in the liquid state into moulds and allowed to set up. After solidification, the material was released from moulds and used after final drying as the Class A1 fireproof tiles suitable e.g. for interior tiling in the vicinity of boilers or fireproof lagging of plants or workshops such as incineration houses etc. in the building industry.

Example 4

Example of another embodiment of the invention is the highly heat- insulating material that has been mixed as a mixture of the following ingredients:

Substance % by weight

Silicic water glass based on sodium silicate Na₂Siθ₃ 20

Expanded granulated filler: pearlite 60

Titanium white: titanium dioxide TiO₂ 10

Ammonium dihydrogen phosphate NH4H₂PO4 5 Cement 5

This material has been produced by mixing the ingredients listed above in a mixer and the resulting mixture was poured in the liquid state into moulds and allowed to set up. After solidification, the material was released from moulds and used as the Class A1 fireproof floor tiles after final drying.

Claims

C L A I M S

1. Fireproof building material based on cement and expanded granulated filler such as granulated polystyrene and/or expanded pearlite, containing cement in the quantity of 5 to 20 percent by weight in the resulting mixture and an expanded granulated filler in the quantity of 20 to 60 percent by weight in the resulting mixture, characterized by that it further contains silicic water glass in the quantity of 20 to 60%, titanium dioxide in the quantity of 5 to 20% and substances from the group of ammonium phosphates in the quantity of 5 to 10%, whereas all the percentages mentioned above are the percentages by weight.

2. Fireproof building material according to claim 1 , characterized by that it contains ammonium dihydrogen phosphate as a substance from the group of ammonium phosphates.

3. Fireproof building material according to claims 1 and 2, characterized by that it contains special-purpose admixtures in the quantity of 0.01 to 5 percent by weight in the resulting mixture.

4. Fireproof building material according to claim 3, characterized by that it contains pigments as admixtures.