WO2010067135A2 - Building mixtures based on cement and/or lime and/or gypsum, rubber as bulk additive and other auxiliary materials - Google Patents

Building mixtures based on cement and/or lime and/or gypsum, rubber as bulk additive and other auxiliary materials Download PDF

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Publication number
WO2010067135A2
WO2010067135A2 PCT/HR2009/000002 HR2009000002W WO2010067135A2 WO 2010067135 A2 WO2010067135 A2 WO 2010067135A2 HR 2009000002 W HR2009000002 W HR 2009000002W WO 2010067135 A2 WO2010067135 A2 WO 2010067135A2
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WIPO (PCT)
Prior art keywords
abr
sbm
mixture
added
cement
Prior art date
Application number
PCT/HR2009/000002
Other languages
French (fr)
Inventor
Ante Grabovac
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Ante Grabovac
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Publication date
Application filed by Ante Grabovac filed Critical Ante Grabovac
Publication of WO2010067135A2 publication Critical patent/WO2010067135A2/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14Compositions 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 calcium sulfate cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions 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
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions 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
    • C04B28/10Lime cements or magnesium oxide cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00672Pointing or jointing materials
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20Resistance against chemical, physical or biological attack
    • C04B2111/28Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/52Sound-insulating materials
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Definitions

  • This invention is related to mixtures, which are used in the building industry.
  • the mixtures are prepared in the manner that organic macromolecular compounds are used as additives to cement and/or lime and/or gypsum and the like mixtures, to improve the desired physical properties of the mixtures as prepared in such a manner.
  • This invention is a solution to several related technical problems.
  • the additives based on this invention are added to a number of standard and less standard building mixtures and products whereby essentially improved insulation characteristics are obtained - thermal and sound insulators, as well as the bearing capacity and resistance to torsion bending of the elements produced.
  • the products as obtained are better thermal and sound insulators, having substantially less specific mass and better physical and mechanical characteristics than the products using standard compounds.
  • German patent application published in 2004 under number DE10354179 contains a discussion on using rubber granulated, where the granules are less than 0,8 mm in diameter, and where specific surface formed by the granules is more than 0,2 m 2 /g of the granules used. Such granules are added to the mixture of cement, other additives and water. The role of used granules in the attenuation of concrete vibration modes has been described.
  • Tiny particles of rubber additives of less than 1 mm in diameter, in particular additives in the form of powder, have low mechanical characteristics because of destructed macromolecular connections due to production treatment, so a reaction to the force applied from the outside is weaker than of particles bigger than 1 mm in diameter, preferably up to 3,5 mm in diameter - as proposed by this invention.
  • the present invention applies: rubber pieces of heterogeneous forms, of sizes and volumes of particles V pa rt; where the surface P pa rt 105 of such volumes V part is much bigger than the spherical surface of the same volume:
  • the particles are such that minimal diameter of the shortest axis of rubber particles is 110 bigger than 1 mm and even up to 5 cm, and the volumes of rubber applied are not of generic form, but of a very irregular one, having irregular convex and concave surfaces.
  • the mentioned rubber is, in accordance with the project and technical requirements (depending on the embodiment and purpose), mixed with: styrofoam in the form of granules, 115 fibrous and other materials, if necessary, and all this is mixed to prepare standard building mixtures based on cement and/or lime and/or gypsum.
  • the present invention has been created on the basis of deliberation about the use of cheap and available materials in building mixtures, which would significantly improve thermal, acoustic and mechanical characteristics, the use of which would be at the same time ecologically and economically acceptable, and where the obtained products could be applied without the need for additional expert knowledge.
  • the present invention also contains a solution dealing with the possibility of making and/or replacing parts which are not the basic and main static elements of an object, for example, the replacement of parts made of bricks, or by Ytong® technology, which cannot be reinforced and have a weak bearing capacity of the object, what is especially important in the anti-
  • ABR additive based on rubber
  • additive based on rubber which can be obtained by breaking, cutting, crushing or milling of all kinds of rubber: new or recycled tires for vehicles and machines; waste rubber from industry (for example, old rubber from belt conveyers, caterpillars), rubber of all other types, for example, raw rubber, foam rubber,
  • the mentioned rubber pieces as obtained are of a very heterogeneous forms, sizes and 150 volumes of particles Vpart; where the surface area P part of these volumes V part is much bigger than the spherical surface size of the same volume:
  • Vpart » P (V sph era) when it is V part * V sp hera
  • the particles are such that minimal diameter of the shortest axis of rubber particles is bigger than 1 mm and even up to 5 cm, and the volumes of rubber applied are not of generic form but of a very irregular one, having irregular convex and concave surfaces.
  • OA as used in this invention, means “other additive”, consisting of: 160
  • polyurethane prepared as grains or pieces, in sizes of 1-30 mm;
  • Termanto® commercially available material which is previously prepared in grains 165 or pieces, in sizes of 1-30 mm;
  • fibrous material - glass fibers and/or other plastic fibers where fiber length is 1-3 cm on the average, and diameter is 0,01 - 1,5 mm, with characteristics not to form clods during mixing process.
  • SBM as used in this invention, means "standard building mixture”, where under this term we imply standard concrete mixtures, mixtures for glazes, mixtures for plasters, building adhesives and other standard building mixtures based on concrete and/or lime with addition of sand, gravel and other crushed stone aggregates.
  • SBM can include water, but do not have to - as it will be discussed in the embodiment examples.
  • SBM concretes, glazes, plasters and building adhesives.
  • concretes are formed using standard ratios of cement, 185 gravel (or crushed stone), sand and water - whereby we get concrete standard building mixture (SBM) according to this invention.
  • Standard building mixture (SBM) obtained in such a manner is modified according to the present invention in the following steps: 190
  • ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-50 % of the SBM volume) so that SBM + OA is making 5-65 % of the volume portion in the standard building mixture (SBM) as defined above, provided that the granulation of ABR does not exceed Vz of the minimal measure (for example, minimal wall
  • cement is added to new mixture, which is now including SBM + ABR + OA, making further 10% of the volume portion of (SBM + ABR + OA), and due to the quantity of cement added, additional triple sand volume quantity of granulation of approximately 200 1/10 of the medium size granules of used particles ABR, and
  • Standard building mixture made strong by cement portion and sand in step 2, is forming membrane around SBM (and OA), which completely encompasses SBM, while OA, if needed, is additionally micro-reinforcing the mixture, in case of adding fibrous materials.
  • Walls made of concrete according to the present invention may be reinforced in the same 215 way as the walls made of SBM having in such a way certain static bearing capacity, although they are not a part of the main static construction.
  • the elements made according to this invention can be produced as ready-made elements and be transported to a building site or can be made on the site, as a continuation of the basic 220 static construction.
  • concrete as modified in this way can also be used as base plate in the building industry where there is a need (in relation to performing documentation) for the previously mentioned insulation characteristics, in terms of 225 temperature and sound - for vibrations of any spectral section.
  • rubber additives in hydraulic concrete prepared according to this invention is decreasing aggressive friction with walls passing along and enables pumping to a 235 higher altitude because of lower specific weight and lower friction.
  • glazes are formed in a simple standard way, using cement, sand in granules of 0,01-4,5 mm and water - and obtaining standard building mixture (SBM).
  • Standard building mixture (SBM) is modified in following steps: 245
  • ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-50 % of the ABR volume) so that ABR + OA is making 10-60 % of the volume portion in the standard building mixture (SBM) as defined above, where granules ABR have sizes between 1-4 mm, 250
  • cement is added to the new mixture, which is now including SBM + ABR + OA, adding further 0,5-10% of the volume portion of (ABR + OA), and due to quantity of cement added, additional triple sand volume quantity of granulation of approximately 1/10 medium size granules of used ABR particles, and
  • Glazes obtained in such a way are used for the lining of surfaces, which, in addition to standard physical characteristics (for example to straighten surface before coating by ceramic tiles, wood or the like) shall have perfect thermal and acoustic insulation characteristics.
  • reinforcement grid is not used for glazes, it is obligatory that OA contain some of the 265 mentioned fibrous materials whose purpose is to make micro-reinforcement.
  • the mixture mentioned above can be made also in the form suitable for dry packaging, and by adding water it can be applied in situ on the desired surface.
  • the surface on which such glaze is applied can be previously also covered by other 270 insulating materials, for example styrofoam — plates, paperboards, nylons, as applied in any order and/or in the standard building process order, and laid on as the final layer.
  • Floor heating, or pipes, cables and other supplying conduits can be built in said glazes.
  • ABR itself with OA additive can be spread in dry incoherent form over a 275 surface, be leveled, covered with nylon foil (lightweight reinforcement overlapped from above) and then covered with new layer prepared according to steps 1., 2., and 3.
  • Mixtures for glazes prepared according to this invention are suitable to be mixed in the so- called Putzmeister® or Mixokret® machines and pumped by adequate pumps to places of 280 their application where again the advantage of using rubber pieces is shown (as well as in the case of concrete used) - less friction and increased pumping altitude available.
  • the portion of OA components depends on and is added according to the project requirements of the object concerned and place for use. 285
  • plasters cement-lime are formed on a simple standard way 290 - using cement, lime and sand in granules of sizes 0,01-4,5 mm and water - whereby obtaining standard building mixtures (SBM).
  • SBM standard building mixtures
  • Standard building mixture SBM is modified in the following steps:
  • ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-50 % of the ABR volume where OA is without fibers in case of mechanical application) so that ABR and OA are making 10-30% of volume portion in the standard building mixture (SBM) as defined above, where ABR granules have size of 1-3,5 mm,
  • OA can also contain fibrous portion, which is added to dry mixture in the case of mechanical application of plaster.
  • Plasters obtained in such a way are applied to vertical and inclined surfaces, ceilings as dry 315 and free of dust, if needed, to a previously applied "concrete drizzle” for better adhesion, and are used for rough or final plastering of surfaces which need plaster of good thermal and acoustic insulation characteristics, of a layer thickness of 0,5-5 cm.
  • the plaster obtained in such a way is used as inside plaster, and also as outside plaster, if the 320 final layer is put over it.
  • plasters gypsum-lime-sand are formed in a simple standard way- using gypsum, lime and sand in granules of sizes 0,01-1,5 mm and water - obtaining thereby standard building mixtures (SBM).
  • Standard building mixture SBM is modified in the following steps: 330
  • ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-50 % of the ABR volume) so that ABR + OA is making 20-50% of the volume portion in the standard building mixture (SBM) as defined above, where ABR granules have size of 1-3,5 mm for manual application, and size of 1-1,25 mm for mechanical
  • Plasters obtained in such a way are applied to vertical and inclined inside surfaces, included 350 ceilings, as dry and free of dust, if needed, to a previously applied "ground” (basic coating) for better adhesion, and are used for fine final plastering of surfaces, which need plasters with good thermal and acoustic insulation characteristics, of a layer thickness of 0,5-5 cm.
  • ground basic coating
  • building adhesive is formed on the basis of cement in a simple standard way-using cement and sand in granules of sizes of 0,01-1,5 mm - whereby a standard building mixture (SBM) is obtained.
  • SBM standard building mixture
  • Water is added during the application process 360 itself allowing the mixture to obtain the desired consistence.
  • Standard building mixture SBM is modified in the following steps:
  • ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-
  • ABR + OA is making 20-50% of the volume portion in the standard building mixture (SBM) as defined above, where ABR granules have sizes of 1-1,5 mm.
  • the building adhesive produced in the way as defined above may be put in standard packaging for further use.
  • This adhesive can be applied as adhesive for 380 ceramic tiles used in households on walls and floors, toilet facilities and the like.
  • ABR mixture as obtained has to be mixed well to be ready for application. Tests show that it is easy spread, applied, flexibly built in, and that it adheres well to any inclination surfaces 395 including ceilings, and due to its low specific weight it has not the tendency to fall off from clean surfaces to which it is applied.
  • the granulation of used ABR can be even up to 3,5 mm, if the layer of adhesive to be applied is not thinner than 5 mm. 400
  • New mixtures as obtained according to the present invention apart from satisfying technical functions and building standards, they give their contribution to the environmental protection, because they are based on waste and recycled materials.
  • they, as embodied 415 in such a way are not harmful to human health, or to the environment (plants and animals) so a problem of their storage or disposal by burning, which would cause additional pollution, has been solved.
  • the building mixtures according to the invention are: suitable for application, functional 420 owing to their appropriate physical and mechanical characteristics, economical for building in and supply, easy available and in accordance with the "green" movement.
  • Solidified building mixtures according to this invention are easy to be disposed of as building waste in the ecologically acceptable way.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Description

BUILDING MIXTURES BASED ON
CEMENT AND/OR LIME AND/OR GYPSUM, RUBBER AS BULK ADDITIVE AND OTHER AUXILIARY MATERIALS Description of the invention
Technical field
This invention is related to mixtures, which are used in the building industry. The mixtures are prepared in the manner that organic macromolecular compounds are used as additives to cement and/or lime and/or gypsum and the like mixtures, to improve the desired physical properties of the mixtures as prepared in such a manner.
Technical problem
This invention is a solution to several related technical problems. In a simple and cheap way the additives based on this invention are added to a number of standard and less standard building mixtures and products whereby essentially improved insulation characteristics are obtained - thermal and sound insulators, as well as the bearing capacity and resistance to torsion bending of the elements produced. The products as obtained are better thermal and sound insulators, having substantially less specific mass and better physical and mechanical characteristics than the products using standard compounds.
State of the art
The state of the art in the examined technical field is significantly complex. Namely, building industry as a technical discipline in which large quantities of materials are used usually has a demand for, on the one hand, exceptional physical characteristics of the materials used, and on the other hand a demand for their acceptable prize. That is the reason why cement and/or lime and/or gypsum, sand (in particular rock crystal sand) gravel and other crushed aggregates based on stone, marble, granite etc. are used most frequently. The basic information can be found on almost all addresses, for example: www.cement.org
Technological progress has generated new materials, and such materials have generated new waste materials, which are suitable to be used in the building industry, where the basic building mixtures have been improved significantly.
So we have found one patent applied for in Great Britain back in 1932, and published under number GB402810 (THE GYPSUM MINES LIMITED), containing a discussion on the addition of rubber, which is cut, granulated or in powder, as additive to cement or gypsum, and with a special addition of curing rubber. If desired, water can be added to mixtures formed in such a way, or the mixture can be used without any limitations on the building site.
A German patent application published in 2004 under number DE10354179 (D. VOLLENSCHAAR and K. D. THIELE) contains a discussion on using rubber granulated, where the granules are less than 0,8 mm in diameter, and where specific surface formed by the granules is more than 0,2 m2/g of the granules used. Such granules are added to the mixture of cement, other additives and water. The role of used granules in the attenuation of concrete vibration modes has been described. A German patent application published in 1993 under number DE41210881 (OBERSTEINER BAUSTOFF GMBH) contains a discussion on the use of plastic waste material, cut old used rubber tires, waste polyester foam in granules and additives whose purpose is to form elements which have perfect thermal and sound insulation characteristics and are used for "covering" buildings.
A PCT international patent application published under number WO2004/078673A1 (UNIVERSITTE DE PICARDIE JULES VERNES) contains a discussion on the use of composite material based on cement and rubber powder and protein foam stimulator with rubber gum particles of less than 1 mm in diameter and with dry rubber portion of 10% to 60%, where said mixture is used for building purposes.
A PCT international patent application published under number WO82/02196 (OY PARTEK AB) contains a discussion on the use of rubber particles, which are added to concrete mixture to prevent surface concrete erosion when water on surface is freezing. Rubber particles, for example, are made of used car tires and have diameter dimension of 10-250 μm.
A Korean patent application published in 2003 under number KR20030093415 (YOUNGBO CHEMICAL CO LTD) contains a discussion on the use of rubber, elastomer and fibers, and foam stimulators added to cement to get lightweight aerated concrete with exceptional characteristics, which it demonstrates as thermal insulator and sound absorber.
A Chinese patent application published in 2007 under number CN101062856 (GUANGDONG UNIVERSITY OF TECHNOLOGY) contains a discussion on the use of rubber in forming flame resistant concretes with high strength of material, where waste rubber gum makes only about 1- 5 % of the mixture, beside other materials used.
All the cited technical solutions are oriented to the fact that rubber has no chemical reactions in the building mixtures, so it has been noted that attempts have been made to use granules, grain particles or rubber powder, of the size as smallest as possible, preferably of less than one millimeter in diameter or even smaller.
The above described procedures and the materials used are not designed for easy application on the building site and have a specific purpose and complicated application, which goes beyond a simple application framework. Moreover, adhesives with additives according to this invention have not been found in the state of the art.
Furthermore, the addition of small rubber particles (in powder form or the like) is producing a technical effect similar to adding sand or gravel, which contains mud, and thereby significantly weakens the characteristics of the cement mixture, so owing to the same only the particles bigger than 1 mm in diameter are used according to this invention.
Tiny particles of rubber additives of less than 1 mm in diameter, in particular additives in the form of powder, have low mechanical characteristics because of destructed macromolecular connections due to production treatment, so a reaction to the force applied from the outside is weaker than of particles bigger than 1 mm in diameter, preferably up to 3,5 mm in diameter - as proposed by this invention. The essence of the invention
To solve the previously specified technical problem, the present invention applies: rubber pieces of heterogeneous forms, of sizes and volumes of particles Vpart; where the surface Ppart 105 of such volumes Vpart is much bigger than the spherical surface of the same volume:
Ppart (Vpart) » P (Vsphera) when it is Vpart «Vsphera where the particles are such that minimal diameter of the shortest axis of rubber particles is 110 bigger than 1 mm and even up to 5 cm, and the volumes of rubber applied are not of generic form, but of a very irregular one, having irregular convex and concave surfaces.
The mentioned rubber is, in accordance with the project and technical requirements (depending on the embodiment and purpose), mixed with: styrofoam in the form of granules, 115 fibrous and other materials, if necessary, and all this is mixed to prepare standard building mixtures based on cement and/or lime and/or gypsum.
The use of these very compounds - the use of said rubber pieces having particles bigger than 1 mm in diameter - is technically preventing the weakening of cement mixtures when adding 120 small rubber particles (for example, in powder or of very tiny granules up to 1 mm) the building in of which has a "mud effect" (of dirty gravel or sand).
Detailed description of the invention
125 The present invention has been created on the basis of deliberation about the use of cheap and available materials in building mixtures, which would significantly improve thermal, acoustic and mechanical characteristics, the use of which would be at the same time ecologically and economically acceptable, and where the obtained products could be applied without the need for additional expert knowledge.
130
The present invention also contains a solution dealing with the possibility of making and/or replacing parts which are not the basic and main static elements of an object, for example, the replacement of parts made of bricks, or by Ytong® technology, which cannot be reinforced and have a weak bearing capacity of the object, what is especially important in the anti-
135 earthquake building process.
This invention will use the following terms definitions:
Definitions
140
"ABR", as used in this invention, means: "additive based on rubber" which can be obtained by breaking, cutting, crushing or milling of all kinds of rubber: new or recycled tires for vehicles and machines; waste rubber from industry (for example, old rubber from belt conveyers, caterpillars), rubber of all other types, for example, raw rubber, foam rubber,
145 recycled footwear rubber and waste rubber from any kind of production process including rubber; where all used rubber products are free from wires, linens, textiles and other non- desired materials. The mentioned rubber pieces as obtained are of a very heterogeneous forms, sizes and 150 volumes of particles Vpart; where the surface area Ppart of these volumes Vpart is much bigger than the spherical surface size of the same volume:
Ppart (Vpart) » P (Vsphera) when it is Vpart * Vsphera
155 where the particles are such that minimal diameter of the shortest axis of rubber particles is bigger than 1 mm and even up to 5 cm, and the volumes of rubber applied are not of generic form but of a very irregular one, having irregular convex and concave surfaces.
"OA", as used in this invention, means "other additive", consisting of: 160
• "styrofoam" of standard form, which is commercially available and can have a form of granules, tiny or big granules/pieces, in sizes of 1-30 mm; and/or
• polyurethane prepared as grains or pieces, in sizes of 1-30 mm; and/or
• Termanto® - commercially available material which is previously prepared in grains 165 or pieces, in sizes of 1-30 mm; and/or
• fibrous material - glass fibers and/or other plastic fibers where fiber length is 1-3 cm on the average, and diameter is 0,01 - 1,5 mm, with characteristics not to form clods during mixing process.
170 "SBM", as used in this invention, means "standard building mixture", where under this term we imply standard concrete mixtures, mixtures for glazes, mixtures for plasters, building adhesives and other standard building mixtures based on concrete and/or lime with addition of sand, gravel and other crushed stone aggregates. SBM can include water, but do not have to - as it will be discussed in the embodiment examples.
175
Mixtures according to the invention
According to the present invention four basic types of improved SBM are defined for concretes, glazes, plasters and building adhesives. 180
CONCRETE
According to the present invention, concretes are formed using standard ratios of cement, 185 gravel (or crushed stone), sand and water - whereby we get concrete standard building mixture (SBM) according to this invention.
Standard building mixture (SBM) obtained in such a manner is modified according to the present invention in the following steps: 190
1. ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-50 % of the SBM volume) so that SBM + OA is making 5-65 % of the volume portion in the standard building mixture (SBM) as defined above, provided that the granulation of ABR does not exceed Vz of the minimal measure (for example, minimal wall
195 thickness) of the mixture used.
2. cement is added to new mixture, which is now including SBM + ABR + OA, making further 10% of the volume portion of (SBM + ABR + OA), and due to the quantity of cement added, additional triple sand volume quantity of granulation of approximately 200 1/10 of the medium size granules of used particles ABR, and
3. all is well mixed in order to distribute ABR (and OA) within the standard building mixture SBM - homogeneously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives. 205
Standard building mixture, made strong by cement portion and sand in step 2, is forming membrane around SBM (and OA), which completely encompasses SBM, while OA, if needed, is additionally micro-reinforcing the mixture, in case of adding fibrous materials.
210 If the mentioned material is used on the position of partition- walls or replacing- walls with lower static bearing capacity, then it is suggested to use styrofoams for OA because of their perfect insulation characteristics.
Walls made of concrete according to the present invention, may be reinforced in the same 215 way as the walls made of SBM having in such a way certain static bearing capacity, although they are not a part of the main static construction.
The elements made according to this invention can be produced as ready-made elements and be transported to a building site or can be made on the site, as a continuation of the basic 220 static construction.
Moreover, according to the present invention, concrete as modified in this way, can also be used as base plate in the building industry where there is a need (in relation to performing documentation) for the previously mentioned insulation characteristics, in terms of 225 temperature and sound - for vibrations of any spectral section.
If concretes according to this invention are produced on industrial scale and transported by concrete mixers, before building in and because of longer time interval between filling and building in, there is a need to effect more aggressive mixing before building in to prevent 230 starting of the binding process, whose result can be clods in mixture. This enables better quality of the building process and flow-rate through concrete-pump.
Furthermore, the use of rubber additives in hydraulic concrete prepared according to this invention is decreasing aggressive friction with walls passing along and enables pumping to a 235 higher altitude because of lower specific weight and lower friction.
GLAZES
240 According to the presented invention, glazes are formed in a simple standard way, using cement, sand in granules of 0,01-4,5 mm and water - and obtaining standard building mixture (SBM).
Standard building mixture (SBM) is modified in following steps: 245
1. ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-50 % of the ABR volume) so that ABR + OA is making 10-60 % of the volume portion in the standard building mixture (SBM) as defined above, where granules ABR have sizes between 1-4 mm, 250
2. cement is added to the new mixture, which is now including SBM + ABR + OA, adding further 0,5-10% of the volume portion of (ABR + OA), and due to quantity of cement added, additional triple sand volume quantity of granulation of approximately 1/10 medium size granules of used ABR particles, and
255
3. all is well mixed in order to distribute ABR (and OA) within the standard building mixture SBM - homogeneously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives.
260 Glazes obtained in such a way are used for the lining of surfaces, which, in addition to standard physical characteristics (for example to straighten surface before coating by ceramic tiles, wood or the like) shall have perfect thermal and acoustic insulation characteristics.
If reinforcement grid is not used for glazes, it is obligatory that OA contain some of the 265 mentioned fibrous materials whose purpose is to make micro-reinforcement.
The mixture mentioned above (SBM - without water + ABR + OA) can be made also in the form suitable for dry packaging, and by adding water it can be applied in situ on the desired surface. The surface on which such glaze is applied can be previously also covered by other 270 insulating materials, for example styrofoam — plates, paperboards, nylons, as applied in any order and/or in the standard building process order, and laid on as the final layer. Floor heating, or pipes, cables and other supplying conduits can be built in said glazes.
Furthermore, ABR itself with OA additive can be spread in dry incoherent form over a 275 surface, be leveled, covered with nylon foil (lightweight reinforcement overlapped from above) and then covered with new layer prepared according to steps 1., 2., and 3.
Mixtures for glazes prepared according to this invention are suitable to be mixed in the so- called Putzmeister® or Mixokret® machines and pumped by adequate pumps to places of 280 their application where again the advantage of using rubber pieces is shown (as well as in the case of concrete used) - less friction and increased pumping altitude available.
The portion of OA components depends on and is added according to the project requirements of the object concerned and place for use. 285
PLASTERS (cement-lime-sand)
According to the present invention plasters cement-lime are formed on a simple standard way 290 - using cement, lime and sand in granules of sizes 0,01-4,5 mm and water - whereby obtaining standard building mixtures (SBM).
Standard building mixture SBM is modified in the following steps:
295 1. ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-50 % of the ABR volume where OA is without fibers in case of mechanical application) so that ABR and OA are making 10-30% of volume portion in the standard building mixture (SBM) as defined above, where ABR granules have size of 1-3,5 mm,
300 2. further 5- 15% of the volume portion of cement + lime from (ABR + OA) is added to the new mixture which is now made of SBM + ABR + OA and due to the quantity of cement added, additional triple sand volume quantity of granulation of approximately 1/3 medium size granules of used particles of ABR, and
305 3. all is well mixed to assure that ABR (and OA) is distributed within the standard building mixture (SBM) - homogenously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives, and when good mixture is obtained, water is added in the required quantity, if needed.
310 If water is excluded from the process - the mixture as obtained is suitable for dry packaging. OA can also contain fibrous portion, which is added to dry mixture in the case of mechanical application of plaster.
Plasters obtained in such a way are applied to vertical and inclined surfaces, ceilings as dry 315 and free of dust, if needed, to a previously applied "concrete drizzle" for better adhesion, and are used for rough or final plastering of surfaces which need plaster of good thermal and acoustic insulation characteristics, of a layer thickness of 0,5-5 cm.
The plaster obtained in such a way is used as inside plaster, and also as outside plaster, if the 320 final layer is put over it.
PLASTERS (gypsum-lime-sand)
325 According to the present invention, plasters gypsum-lime-sand are formed in a simple standard way- using gypsum, lime and sand in granules of sizes 0,01-1,5 mm and water - obtaining thereby standard building mixtures (SBM).
Standard building mixture SBM is modified in the following steps: 330
1. ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-50 % of the ABR volume) so that ABR + OA is making 20-50% of the volume portion in the standard building mixture (SBM) as defined above, where ABR granules have size of 1-3,5 mm for manual application, and size of 1-1,25 mm for mechanical
335 application;
2. further 5-15% of the volume portion of gypsum + lime from (ABR + OA) is added to new mixture which now made of SBM + ABR + OA, and
340 3. all is well mixed to assure that ABR (and OA) are distributed within the standard building mixture (SBM) - homogenously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives, and when good mixture is obtained, water is added in the required quantity, if needed. 345 If water is excluded from the process - the mixture as obtained is suitable for dry packaging. OA can also contain a fibrous portion, which is added to dry mixture in the case of mechanical application of plaster.
Plasters obtained in such a way are applied to vertical and inclined inside surfaces, included 350 ceilings, as dry and free of dust, if needed, to a previously applied "ground" (basic coating) for better adhesion, and are used for fine final plastering of surfaces, which need plasters with good thermal and acoustic insulation characteristics, of a layer thickness of 0,5-5 cm.
355 BUILDING ADHESIVES
According to the present invention building adhesive is formed on the basis of cement in a simple standard way-using cement and sand in granules of sizes of 0,01-1,5 mm - whereby a standard building mixture (SBM) is obtained. Water is added during the application process 360 itself allowing the mixture to obtain the desired consistence.
Standard building mixture SBM is modified in the following steps:
365 1. ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5-
50 % of the ABR volume) so that ABR + OA is making 20-50% of the volume portion in the standard building mixture (SBM) as defined above, where ABR granules have sizes of 1-1,5 mm.
370 2. further 5-10% of the volume portion of cement from (ABR + OA) is added to new mixture which is now made of SBM + ABR + OA, and
3. all is well mixed to assure that ABR (and OA) is distributed within the standard building mixture (SBM) - homogenously, preferably by mixers with sharp edges, 375 which is not a condition, to prevent forming clods of material without adhesives.
The building adhesive produced in the way as defined above (but mixed without water) may be put in standard packaging for further use. This adhesive can be applied as adhesive for 380 ceramic tiles used in households on walls and floors, toilet facilities and the like.
Moreover, it is possible (in accordance with the procedure mentioned above) to add ABR and OA to any kind of industrially packed building adhesive, for example of TERATEKT G® 385 type (producer "Samoborka", Croatia), and, before the usage itself, water to obtain sufficient homogeneity and humidity of the mixture suitable for concrete application.
Moreover, the same procedure may be repeated with other adhesives for inside application intended for ceramic tiles, stone, marble, granite or similar materials, such as, for example 390 WDSV® (Baumit) adhesive for styrofoam where ABR is added, in the ratio of 10-50% of the volume quantity, directly to the mixture package.
ABR mixture as obtained has to be mixed well to be ready for application. Tests show that it is easy spread, applied, flexibly built in, and that it adheres well to any inclination surfaces 395 including ceilings, and due to its low specific weight it has not the tendency to fall off from clean surfaces to which it is applied.
The granulation of used ABR can be even up to 3,5 mm, if the layer of adhesive to be applied is not thinner than 5 mm. 400
It is not recommended to apply the mentioned mixture to outside open surfaces or to final layers, which will not be finally treated.
Industrial applicability
405
Industrial applicability of the present invention is not in question. This invention concerns modifications of the previously used standard building mixtures, where, according to the invention, other materials can be added to the same mixtures, in particular macromolecular waste or similar materials based on rubber, which are modulating and improving physical
410 characteristics of standard building mixtures in an unexpected way.
New mixtures as obtained according to the present invention, apart from satisfying technical functions and building standards, they give their contribution to the environmental protection, because they are based on waste and recycled materials. In addition to this, they, as embodied 415 in such a way, are not harmful to human health, or to the environment (plants and animals) so a problem of their storage or disposal by burning, which would cause additional pollution, has been solved.
The building mixtures according to the invention are: suitable for application, functional 420 owing to their appropriate physical and mechanical characteristics, economical for building in and supply, easy available and in accordance with the "green" movement.
Their application is universal including housings, working areas, sports facilities, and the like. They are durable and safe to be used. 425
Solidified building mixtures according to this invention, are easy to be disposed of as building waste in the ecologically acceptable way.

Claims

430 1. A building mixture based on cement and/or lime and/or gypsum, rubber and other auxiliary materials, where a standard building mixture (SBM) is used as the basis for a new building mixture, characterized by the fact, that the new mixture is obtained in the way that the (SBM) is added:
- an additive based on rubber (ABR) - pieces of heterogeneous forms, of sizes and 435 volumes of particles Vpart; where the surface Ppart of such volumes Vpart is much bigger than the surface of spheres of the same volume:
Ppart (Vpart) » P (Vsphera) when it is Vpart «Vsphera where the particles are such that minimal diameter of the shortest axis of rubber particles is bigger than 1 mm and even up to 5 cm, and the volumes of rubber applied 440 are not of generic form, but of a very irregular one, having irregular convex and concave surfaces, and
- possibly other additive (OA) consisting of styrofoam and/or polyurethane and/or Termanto® with particles sizes of 1-30 mm and/or synthetic fibrous materials whose length is 1-3 cm on the average and diameter 0,01 - 1,5 mm.
445
2. A process for obtaining a concrete building mixture according to claim 1 , characterized by the fact, that the process is carried out in the following steps:
(A) ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5- 50 % of SBM volume) so that ABR + OA is making 5-65 % of the volume portion in
450 the standard building mixture (SBM) as defined above, provided that the granulation of ABR does not exceed '/. of the minimal measure of mixture used,
(B) cement is added to the new mixture, which is now including SBM + ABR + OA, making further 10% of the volume portion of (SBM + ABR + OA), and due to the quantity of cement added, additional triple sand volume quantity of granulation of
455 approximately 1/10 of the medium size granules of used ABR particles, and
(C) all is well mixed in order to distribute ABR (and OA) within the standard building mixture SBM - homogeneously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives.
460 3. A product obtained according to claim 2, characterized by the fact, that it is used as a partition- wall, a prefabricated element or other building element made of cement having low specific weight and improved insulation, thermal and acoustic characteristics.
465 4. A process for obtaining building mixture for glazes according to claim 1, where SBM consists of cement, sand in granules in size of 0,01-4,5 mm and water optionally added during the preparation process or afterwards, characterized by the fact, that the process is carried out in the following steps:
(A) ABR is added to SBM mixture and, if needed, OA is added in the quantity of 5- 470 50 % of the ABR volume so that SBM + OA is making 10-60 % of the volume portion in standard building mixture (SBM) as defined above, where granules have sizes between 1-4 mm,
(B) cement is added to new mixture, which is now including SBM + ABR + OA, adding further 0,5-10% of the volume portion of (ABR + OA), and due to the
475 quantity of cement added, additional triple sand volume quantity of granulation of approximately 1/10 of the medium size granules of used SBM particles, and
(C) all is well mixed in order to distribute ABR (and OA) within the standard building mixture ABR - homogeneously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives. 480
5. A process for obtaining building mixture for plasters cement-lime according to claim 1, where SBM consists of cement, lime and sand in granules of sizes 0,01-4,5 mm and water, optionally added during the preparation process or afterwards, characterized
485 by the fact, that process is carried out in the following steps:
(A) ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5— 50 % of the ABR volume) where OA is without fibers in case of mechanical application - so that ABR + OA is making 10-30% of the volume portion in the standard building mixture (SBM) as defined above, where ABR granules have sizes of
490 1-3,5 mm,
(B) further 5-15% of the volume portion of cement + lime from (ABR + OA) is added to the new mixture which is now made of SBM + ABR + OA, and due to the quantity of cement added, additional triple sand volume quantity of granulation of approximately 1/3 medium size granules of used particles of ABR, and
495 (C) all is well mixed to assure that ABR (and OA) is distributed within the standard building mixture (SBM) - homogenously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives.
6. A process for obtaining building mixture for plasters gypsum-lime according to claim 500 1, where SBM consists of gypsum, lime and sand in granules of sizes 0,01-1,5 mm and water, optionally added during the preparation process or afterwards, characterized by the fact, that process is carried out in the following steps:
(A) ABR is added to SBM mixture - and, if needed, OA is added in the quantity of 5- 50 % of the ABR volume where OA is without fibers in case of mechanical
505 application - so that ABR + OA is making 20-50% of the volume portion in the standard building mixture (SBM) as defined above, where ABR granules have sizes of 1-3,5 mm for manual application, and 1-1,25 mm for mechanical application;
(B) further 5-15% of the volume portion of gypsum + lime from (ABR + OA) is added to new mixture which is now made of SBM + ABR + OA, and
510 (C) all is well mixed in order to assure that ABR (and OA) are distributed within the standard building mixture SBM — homogeneously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives.
515 7. A process for obtaining a building mixture as a building adhesive according to claim
1, where SBM consists of cement and sand in granules of sizes 0,01-1,5 mm and water optionally added during the preparation process or afterwards, characterized by the fact, that process is carried out in the following steps:
(A) ABR is added to SBM mixture (and, if needed, OA is added in the quantity of 5- 520 50 % of the ABR volume) so that ABR + OA is making 20-50% of the volume portion in the standard building mixture (SBM) as defined above, where ABR granules have sizes 1-1,5 mm;
(B) further 5-10% of the volume portion of cement from (ABR + OA) is added to the new mixture, which is now made of SBM + ABR + OA, and
525 (C) all is well mixed in order to assure that SBM (and OA) is distributed within the standard building mixture SBM - homogeneously, preferably by mixers with sharp edges, which is not a condition, to prevent forming clods of material without adhesives.
530 8. A product obtained according to claims 4-7 characterized by the fact that SBM is prepared without water and that mixture obtained as a result after steps (A), (B) and (C) is packed in dry condition and applied by using water and mixed prior to the application under the same conditions as the initial SBM.
535 9. A process for obtaining improved building adhesive for inside application and sticking of ceramic material, stone, marble, granite and similar materials characterized by the fact, that it is obtained by mixing up to 50% of the volume portion of ABR and OA and industrially packed adhesives for the inside application.
540 10. A product obtained according to claims 4-7 and 9, or in dry package, according to claim 8 with the addition of water, characterized by the fact, that it has lower specific weight, improved thermal and acoustic insulation characteristics — as thermal and acoustic insulator - and vibrations suppressor.
PCT/HR2009/000002 2008-12-12 2009-01-16 Building mixtures based on cement and/or lime and/or gypsum, rubber as bulk additive and other auxiliary materials WO2010067135A2 (en)

Applications Claiming Priority (2)

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HR20080649A HRPK20080649B3 (en) 2008-12-12 2008-12-12 Building mixtures based on cement and/or lime and/or gypsum, gum and the other auxiliary materials
HR20080649A 2008-12-12

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3127885A1 (en) * 2015-08-06 2017-02-08 Ceské vysoké ucení technické v Praze Cement composite material with inhomogeneous textile crushed pieces
CN112266206A (en) * 2020-10-29 2021-01-26 南京工业大学 Semi-dry mixing method preparation technology for waste rubber particle reinforced composite soil sample
CN113929376A (en) * 2020-06-29 2022-01-14 比亚迪股份有限公司 Rubber concrete, preparation method thereof and bridge

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3127885A1 (en) * 2015-08-06 2017-02-08 Ceské vysoké ucení technické v Praze Cement composite material with inhomogeneous textile crushed pieces
CN113929376A (en) * 2020-06-29 2022-01-14 比亚迪股份有限公司 Rubber concrete, preparation method thereof and bridge
CN112266206A (en) * 2020-10-29 2021-01-26 南京工业大学 Semi-dry mixing method preparation technology for waste rubber particle reinforced composite soil sample

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HRP20080649A2 (en) 2010-06-30

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