WO2011058574A2 - Composition conçue pour la construction de bâtiments - Google Patents

Composition conçue pour la construction de bâtiments Download PDF

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Publication number
WO2011058574A2
WO2011058574A2 PCT/IN2010/000024 IN2010000024W WO2011058574A2 WO 2011058574 A2 WO2011058574 A2 WO 2011058574A2 IN 2010000024 W IN2010000024 W IN 2010000024W WO 2011058574 A2 WO2011058574 A2 WO 2011058574A2
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WO
WIPO (PCT)
Prior art keywords
mass
amount
composition
total composition
building construction
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Application number
PCT/IN2010/000024
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English (en)
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WO2011058574A3 (fr
Inventor
Joshi Pradeep Vasant
Joshi Shilpa Pradeep
Original Assignee
Joshi Pradeep Vasant
Joshi Shilpa Pradeep
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Application filed by Joshi Pradeep Vasant, Joshi Shilpa Pradeep filed Critical Joshi Pradeep Vasant
Priority to PCT/IN2010/000024 priority Critical patent/WO2011058574A2/fr
Priority to CH00444/11A priority patent/CH702564B1/it
Priority to AU2010100046A priority patent/AU2010100046A4/en
Publication of WO2011058574A2 publication Critical patent/WO2011058574A2/fr
Publication of WO2011058574A3 publication Critical patent/WO2011058574A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/06—Acrylates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0045—Polymers chosen for their physico-chemical characteristics
    • C04B2103/0065—Polymers characterised by their glass transition temperature (Tg)
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/72—Repairing or restoring existing buildings or building materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to a composition suitable for use in the building construction industry.
  • Metar composition includes binding mortar, adhesive mortar, plastering mortar, grouting mortar and crack filler.
  • mortars were mainly based on mineral binders like lime, cement and gypsum.
  • the mortars have mainly been used as adhesives for clay bricks, fly ash bricks, aerated concrete blocks, and cement blocks, as a plaster/render, as crack filler and for coating walls.
  • the Lime mortar composed of lime, an aggregate such as sand, and water is one of the oldest known types of mortars, used even in the Indus valley civilization. With the introduction of Portland cement, the use of lime mortar in newer constructions gradually declined. However the soft, porous properties of lime mortar provide certain advantages when working with building materials such as natural stone and terracotta.
  • cement is the vital binding agent in concretes, mortars and renders, and is used for the production of walling blocks and roofing tiles. Since its invention in the first half of the 19th century, Portland cement, a type of cement, has become the most widely available cementitious material due to its ease of use, quick setting properties and compressive strength. In conventional mortars, typically Portland cement, sand/silica and water and optionally other additives act as the main ingredients along with some additives like waterproofing agents, fibers, re-dispersible polymers and extenders are mixed using on-site mixing technology and applied on to the blocks/bricks. After application of the mortar curing, essentially with water for at least seven days to complete the hydration process within the mortar and to attain the optimum strength of the mortar bond, is required.
  • the most common practice of mortaring in masonry work involves on site mixing of cement, sand and water in a predefined ratio and the wet mortar is applied to building blocks.
  • the quality of such a mortar depends on the raw materials used, their correct mixing ratio, the homogeneity of the mixture, the quality and the quantity of water used and the consistency of the final mortar.
  • the consistency of such on site mixed mortars may vary due to errors that can occur during mixing of the raw materials, affecting the homogeneity of the final product which results in an inconsistent mortar mixture.
  • the current practices of construction involve separate inventory management and material handling on site. This involves a lot of time, manpower as well as energy.
  • US Patent 4229329 discloses a fire retardant coating composition which is used as a paint or as a mastic comprising fly ash and polymer emulsion binder.
  • the composition disclosed in the abovementioned cited patent document comprises ultra-fine pulverized ash in an amount of 7- 31% weight of the composition; a binder comprising a low viscosity vinyl acrylic type emulsion polymer in an amount of 1-40% by weight of the composition; fillers comprising gypsum or fiberglass in an amount of 20%-30% by wt. of the total composition; water constituting from 8-48% by weight of the composition; and additives like drying agent, defoamer, plasticizer and the like.
  • composition disclosed in the cited patent document is specifically employed as a fire retardant coating composition for vertical surfaces and not as a mortar or cementitious material in the construction industry.
  • fillers and additives like defoaming agents and drying agents are added in the abovementioned composition in such proportions so as to essentially obtain a fire retardant coating composition.
  • PCT application WO09007994 discloses a composition for the production of fly ash pre-polymerized resin emulsion composite useful as a mortar, as a crack filler and as a plaster/render.
  • the composition disclosed in the abovementioned patent application comprises ultra fine pulverized fly ash and bottom ash, low-viscosity vinyl acetate as a polymer binder, water, fillers and one or more additives.
  • the composition disclosed in the abovementioned application is a ready to use material and hence the consistency and homogeneity of the material is assured.
  • the required bond strength of the mortar has not been achieved when low-viscosity vinyl acetate and fly ash were employed in the composition.
  • a dry composition for preparing a flowable mixture for acoustic sound insulation.
  • a dry composition includes at least 50% by volume of rubber crumb, aggregate material including at least 10% by total dry composition volume pulverized fuel ash, and a hydraulic binding agent including both cement based compound of between 5 and 20% by total dry composition and preferably between 10 and 15% and a hydraulic polymeric binder which is a copolymer of Ethylene-vinyl acetate.
  • US Patent 5244304 discloses a paving composition which is used in patching a depression in asphalt pavement.
  • the composition comprises cement binder, water dispersible latex polymer binder based on ethylene-vinyl acetate copolymer, filler composition, water and additives.
  • the invention also provides a method for using the composition in paving, repairing or filling depressions in asphalt pavement.
  • compositions disclosed in the cited patent documents are designed as a job-site mixing compositions in which the applicator mixes the raw materials with the water available on site before applying it on the surface and hence the quality of the final product is not maintained because of the abrupt mixing of the raw materials.
  • Another object of the present invention is to provide a construction composition which can be used as a mortar, plaster/render, crack filler and as a plaster repair.
  • Another object of the present invention is to provide a construction composition which on application does not need any pre-wetting and/or post curing with water.
  • Another object of the present invention is to provide a construction composition with extended pot life and shelf life.
  • Yet another object of the present invention is to provide a construction composition which is non hazardous for the applicator and the end user.
  • Yet another object of the present invention is to provide a construction composition which saves time in application, manual labour.
  • Still another object of the present invention is to provide a construction composition which uses the major pollutants and hence offers an environmental friendly composition.
  • Still further object of the present invention is to provide a construction composition which is cost-effective.
  • Still further object of the present invention is to provide a construction composition which is based on air drying/curing.
  • One more object of the present invention is to provide a construction composition which has adequate bond strength and offers good weather resistance.
  • composition suitable for use in building construction comprising
  • a thickener in an amount of about 0.15% to about 4% of the mass of the total composition
  • a pH stabilizer in an amount of about 0.45% to about 1.5% of the mass of the total composition
  • a preservative in an amount of about 0.05% to about 1.25%) of the mass of the total composition
  • coalescing agent in an amount of about 0.22% to about 2.25% of the mass of the total composition
  • an anionic pre-polymerized binder having intrinsic viscosity in the range of 250 cps to 4000 cps in an amount of about 2% to about 45% of the mass of the total composition
  • g. bottom ash of particle size of above 45 microns in an amount of about 4.5% to about 76% of the mass of the total composition h. silica particle mixture of particle size in the range of about 100 microns to about 4000 microns in an amount of about 0% to about 73.5% of the mass of the total composition;
  • a filler in an amount of about 0 % to about 55 % of the mass of the total composition
  • At least one additive selected from a group of additives consisting of a water proofing/repellant agent, dispersing agent and a wax emulsion.
  • the water is demineralized water.
  • the demineralized water is obtained by reverse osmosis.
  • the water is distilled water or deionized water, soft water and water is free from bacteria.
  • the thickener is at least one selected from cellulosic or non-cellulosic compounds which include acrylic polymer, acrylic emulsion copolymer, Hydroxyethylcellulose, acrylic copolymer and crystalline hydrated magnesium aluminium silicate.
  • the thickener is an acrylic polymer.
  • the pH stabilizer is selected from a group consisting of liquid ammonia, triethylamine, ammonium chloride and ammonium hydroxide.
  • the pH stabilizer is liquid ammonia having concentration in the range of 15% to 30%.
  • the pH stabilizer is triethylamine.
  • the preservative is selected from a group consisting of chloromethyl- methylisothiazolone formaldehyde, carbendazim-octylisothiazolone and isothiazolinones.
  • the coalescing agent is selected from a group consisting of monoethylene glycol, diethylene glycol, propylene glycol, taxonol, mixed xylene, gentamicin sulphate and hexane.
  • the coalescing agent is either mixed xylene or diethylene glycol or gentamicin sulphate.
  • the anionic pre-polymerized binder is water dispersible.
  • the anionic pre-polymerized binder is a homopolymer.
  • the anionic pre-polymerized binder is selected from a group consisting of acrylic polymer, styrene polymer, CNSL (Cashew nut shell liquid) emulsion, shellac emulsion, low viscosity vinyl acrylic polymer, elastomeric acrylic emulsion and silicon emulsion.
  • the anionic pre-polymerized binder is an acrylic polymer or styrene polymer.
  • the anionic pre-polymerized binder is a copolymer of acrylic and styrene.
  • the anionic pre-polymerized acrylic and styrene copolymer are in the ratio of 70 to about 30 by mass.
  • the anionic pre-polymerized acrylic and styrene copolymer are in the ratio of 50 to about 50 by mass.
  • the glass transition temperature of the anionic pre-polymerized binder is in range of about 10°C to 50°C.
  • the glass transition temperature of the anionic pre-polymerized binder is in range of about 10°C to 30°C.
  • the anionic pre-polymerized binder contains particulate monomeric units in the form of suspended monomeric particles having particle size below 8 microns preferably in the range of about 4 to 5 microns.
  • the pH of the anionic prepolymerized binder is in the range of 3 to 10.
  • the bottom ash is ash obtained from a wet or dry bottom coal combustion boiler and has moisture content less than about 0.5%.
  • said composition includes fly ash in an amount of 0% to 76% of the mass of the total composition.
  • the silica used is at least one silica derived from a group consisting of crystalline silica derived from rice husk, fumed silica, foundry silica, quarry silica, river bed silica or seashore silica which is used after desalinization.
  • the composition comprises silica particle mixture having particle sizes of 1.7 mm, 1.4 mm, 0.4 mm and 0.2mm respectively in proportions of about 10%, 30%, 14% and 55% of the total mass of silica.
  • said composition comprises silica particle mixture _ having particle size of 0.4mm and 0.2 mm respectively in the proportions of 93.33% and 6.67% of the total mass of silica.
  • said composition comprises silica particle mixture having particle size of 0.2 mm and 0.6 mm respectively in the proportions of about 10% and about 90%.
  • the stone grit has irregular shapes and has a particle size in the range of 1mm to 4mm.
  • the stone grit is selected from the group of stones selected from consisting of Shahabad, kotta, basalt, granite, sandstone, limestone, marble, soapstone and slate.
  • filler is at least one filler selected from a group of fillers consisting of coir dust, coconut powder, polystyrene balls, plastic wastes, rubber crumbs, glass beads, coir mesh, cork chips, natural fibers, synthetic fibers, glass fibers, ceramic spheres, powdered titanium oxide, calcium carbonate, iron oxide, mica, vermiculite and perlite.
  • the extender is at least one extender selected from a group of extenders consisting of china clay, super chalk, talc, barites, quartz powder and dolomite.
  • the composition contains wax emulsion in an amount of about 0.1% to about 5% of the mass of the total composition.
  • the water proofing/repellant agent is calcium stearate.
  • the present invention provides a composition suitable as a mortar in the building construction comprising the following ingredients:
  • acrylic polymer in an amount of about 1.25% to about 1.5 % of mass of the total composition
  • silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about 22% to about 28% of the mass of the total composition
  • stone grit having particle size of 4 mm in an amount of about 20% to about 24% of mass of the total composition
  • stone grit having particle size of 1 mm in an amount of about 6% to about 8% of mass of the total composition.
  • the present invention provides a composition suitable as a plaster/render in the building construction, comprising the following ingredients:
  • liquid ammonia in an amount of about 0.25% to about 0.39% of the mass of the total composition
  • silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about 22% to about 27% of the mass of the total composition.
  • the present invention provides a composition suitable as a grouting mortar in the building construction, comprising the following ingredients:
  • liquid ammonia in an amount of about 0.3 % to about 0.7 % of the mass of the total composition
  • silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about 22% to about 27% of the mass of the total composition
  • stone grit having particle size of 4 mm in an amount of about 25% to about 27% of mass of the total composition
  • the present invention provides a composition suitable as a repair mortar in the building construction, comprising the following ingredients:
  • acrylic polymer in an amount of about 2% to about 2.4 % of mass of the total composition
  • liquid ammonia in an amount of about 0.5 % to about 0.8 % of the mass of the total composition
  • bottom ash of particle size in the range of 60 micron to 80 micron in an amount of about 28% to about 32% of the mass of the total composition
  • silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about 32% to about 36% of the mass of the total composition
  • stone grit having particle size of 1 mm in an amount of about 5% to about 5.5% of mass of the total composition.
  • the present invention provides a composition suitable as crack filler in the building construction, comprising the following ingredients:
  • acrylic polymer in an amount of about 1% to about 1.27 % of mass of the total composition
  • silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about 32% to about 33.5% of the mass of the total composition.
  • the thickener and the pH stabilizer are added simultaneously.
  • the process step (a) is carried out at a speed of about 1400-1500 rpm.
  • the process step (c ) is carried out at a speed of about 600-700 rpm.
  • the process steps result in a homogenous composition.
  • at least one additive selected from a group of additives consisting of a water proofing/repelling agent ,a dispersing agent and a wax emulsion is incorporated in said composition.
  • the present invention relates to a composition which is suitable for use in building construction as an adhesive for all sorts of masonry units such as clay bricks, fly ash bricks, aerated concrete bricks, cement blocks and building blocks for civil construction activities as a mortar, plaster/render, repair mortar, grouting mortar and crack filling material and also as a fire and heat resistant plaster.
  • the product is designed to be used in building construction industry as a self-curing, crack resistant, eco-friendly, ready to use.
  • the composition provided in accordance with the present invention is in ready to use form hence no on-site mixing of the raw materials with water is required and thus, this enables to control both the quality and quantity of the composition.
  • composition in accordance with the present invention is free from conventional Portland cement hence no pre-wetting and post curing with water is required. This not only saves the water but also the construction time. Also, the composition provided in accordance with the present invention uses one of the major pollutants like fly ash and/or bottom ash of the environment thus helps in reducing environmental pollution. Moreover, the silica used in the composition is prepared in accordance with the present invention and need not be river bed side silica which also protects ecology.
  • a composition suitable for use in building construction comprising water in an amount of about 4% to about 49% of the mass of the total composition; a thickener in an amount of about 0.25% to about 4% of the mass of the total composition; a pH stabilizer in an amount of about 0.1% to about 1.5% of the mass of the total composition; a preservative in an amount of about 0.05% to about 1.25% of the mass of the total composition; a coalescing agent in an amount of about 0.25% to about 1.25% of the mass of the total composition; an anionic pre-polymerized binder having intrinsic viscosity in the range of 250 cps to 4000 cps and an amount of about 2% to about 45% of the mass of the total composition; bottom ash of particle size of above 45 microns in an amount of about 5% to about 75% of the mass of the total composition; silica particle mixture with particle size in the range of about 100 microns to about 4000 microns in an amount
  • the water in the composition is used as a medium and can be demineralized water which is obtained from distillation process, distilled water, deionized water or a soft water free from bacteria.
  • the amount of water employed in said composition depends on the use to which the composition is to be applied.
  • the thickener is employed in said composition and which can be at least one selected from cellulosic or non-cellulosic compounds which include acrylic polymer, acrylic emulsion copolymer, Hydroxyethylcellulose, acrylic copolymer and crystalline hydrated magnesium aluminium silicate.
  • the thickener employed in said composition is an acrylic polymer.
  • the pH stabilizer is incorporated in said composition to maintain the alkaline pH thereby making the composition resistant to the acidic conditions and can be at least one selected from a group consisting of liquid ammonia, triethylamine, ammonium chloride and ammonium hydroxide.
  • the pH stabilizer is liquid ammonia having concentration in the range of 15 to 30.
  • the pH stabilizer is triethylamine.
  • the preservative can be at least one selected from a group consisting of chloromethyl-methylisothiazolone formaldehyde, carbendazim-octylisothiazolone and isothiazolinones.
  • the coalescing agent in said composition helps in film formation after application of said composition.
  • the coalescing agent can be at least one selected from a group consisting of monoethylene glycol, diethylene glycol, propylene glycol, taxonol, mixed xylene, gentamicin sulphate and hexane.
  • the coalescing agent used is mixed xylene.
  • the coalescing agent is diethylene glycol.
  • the coalescing agent employed in the present inyention is gentamicin sulphate.
  • the anionic pre-polymerized binder which employed in said composition is either homopolymer or a copolymer.
  • the binder enhances the applicability, flow properties and strength and weather sustenance of the final product sustenance.
  • the proportions of the binders used in said composition varies as per the purpose of the product and its desired properties and performance.
  • the anionic pre-polymerized binder can be at least one binder selected from a group consisting of acrylic polymer, styrene polymer, CNSL (cashew nut shell liquid) emulsion, shellac emulsion, low viscosity vinyl acrylic polymer, elastomeric acrylic emulsion and silicon emulsion.
  • Said composition made with anionic pre-polymerized acrylic polymer as a binder gives excellent outdoor durability and excellent adhesion under damp or dry conditions.
  • the anionic pre-polymerized binder is a copolymer of acrylic and styrene.
  • the ratio of acrylic to styrene in said composition is of about 70 to about 30 by mass.
  • the ratio of acrylic to styrene in said composition is of 50 to about 50 by mass.
  • the glass transition temperature of the anionic pre-polymerized binder is in range of about 10°C to 50°C, preferably in the range of about 10°C to 30°C.
  • the pH of the anionic prepolymerized binder is in the range of 3 to 10.
  • the anionic pre-polymerized binder contains particulate monomeric units with suspended monomeric particles having particle size below 8 microns, preferably in the range of 4 to 5 microns.
  • the bottom ash is ash obtained from a wet bottom coal combustion boiler or from the dry bottom coal combustion boiler.
  • the bottom ash used in the present invention has moisture content less than about 0.5 %.
  • the bottom ash when used with other inert inorganic materials gives bulk to the product.
  • said composition includes fly ash in an amount of 0% to 55 % of the mass of the total composition. The ratio of fly ash and bottom ash in said composition is in the range of about 10:90 to about 90: 10.
  • said composition contains crystalline silica which is derived from rice husk.
  • the silica can be fumed silica.
  • Other sources are river bed silica, quarry silica, foundry silica.
  • said composition comprises a silica particle mixture having particle size less than 2 mm.
  • said composition comprises a silica particle mixture having particle size of 1.7 mm, 1.4 mm, 0.4 mm and 0.2mm respectively in the proportions of about 10%, 30%, 14% and 55% of the total mass of silica.
  • said composition comprises silica particle mixture having particle size of 0.4mm and 0.2 mm respectively in the proportions of 93.33% and 6.67% of the total mass of silica.
  • said composition comprises silica particle mixture having particle size of 0.2 mm and 0.6 mm respectively in the proportions of 10% and 90%.
  • said composition uses stone grit having particle size in the range of 1mm to 4mm with irregular shapes.
  • the stone can be at least one selected from a group of stones consisting of Shahabad, kotta, basalt, granite, sandstone, limestone, marble, soapstone and slate.
  • said composition optionally uses a filler which can be at least one selected from a group of fillers consisting of coir dust, coconut powder, polystyrene balls, plastic wastes, rubber crumbs, glass beads, coir mesh, cork chips, natural fibers, synthetic fibers, glass fibers, ceramic spheres, powdered titanium dioxide, calcium carbonate iron oxide, mica, vermiculite and perlite.
  • the filler is in an amount of about 0% to about 55% of the mass of the total composition.
  • the composition optionally contains an extender and can be at least one extender selected from a group of extenders consisting of china clay, super chalk, talc, barites, quartz powder and dolomite.
  • the extender is in an amount of about 0% to about 75% of the mass of the total composition.
  • said composition optionally contains wax emulsion in an amount of about 0% to about 5% of the mass of the total composition.
  • said composition optionally contains water proofing/repelling agent.
  • composition suitable for use in building construction disclosed in accordance with the present invention is in the form of a wet mixture which is 'ready to use.
  • composition suitable for use in building construction disclosed in accordance with the present invention is free from Portland cement.
  • the present invention provides a composition suitable as a mortar in building construction which comprises demineralized water in an amount of about 32% to about 37% of mass of the total composition; acrylic polymer in an amount of about 1.25% to about 1.5 % of mass of the total composition; liquid ammonia in an amount of about 0.38% to about 0.45% of the mass of the total composition; chloromethyl-methylisothiazolone formaldehyde in an amount of about 0.6 % to about 1.2% of the mass of the total composition; gentamicin sulphate in an amount of about 0.3% to about 0.5% of the mass of the total composition; water dispersible anionic pre-polymerized Acrylic-styrene binder in an amount of about 6% to about 6.6% of the mass of the total composition; bottom ash of particle size above 45 microns in an amount of about 28% to about 34% of the mass of the total composition; silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about 22% to about 2
  • the present invention provides a composition suitable as a plaster/render in building construction which comprises demineralized water in an amount of about 32% to about 34% of mass of the total composition; acrylic polymer in an amount of about 0.9% to about 1.9 % of mass of the total composition; liquid ammonia in an amount of about 0.25% to about 0.39% of the mass of the total composition; chloromethyl- methylisothiazolone formaldehyde in an amount of about 0.05 % to about 1% of the mass of the total composition; gentamicin sulphate in an amount of about 0.3% to about 0.5% of the mass of the total composition; water dispersible anionic pre-polymerized Acrylic-styrene binder in an amount of about 6% to about 6.5% of the mass of the total composition; bottom ash of particle size above 45 microns in an amount of about 25% to about 35% of the mass of the total composition; and silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about
  • the present invention provides a composition suitable as a grouting mortar in building construction which comprises demineralized water in an amount of about 26.3% to about 27% of mass of the total composition; acrylic polymer in an amount of about 1.2% to about 2 % of mass of the total composition; liquid ammonia in an amount of about 0.3 % to about 0.7 % of the mass of the total composition; carbendazim-octylisothiazolone in an amount of about 0.5 % to about 1% of the mass of the total composition; gentamicin sulphate in an amount of about 0.3% to about 0.6% of the mass of the total composition; water dispersible anionic pre-polymerized Acrylic-styrene binder in an amount of about 6% to about 6.6% of the mass of the total composition; bottom ash of particle size above 45 microns in an amount of about 28% to about 32% of the mass of the total composition; silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of
  • the present invention provides a composition suitable as a repair mortar in building construction which comprises demineralized water in an amount of about 21 % to about 22.3% of mass of the total composition; acrylic polymer in an amount of about 2% to about 2.4 % of mass of the total composition; liquid ammonia in an amount of about 0.5 % to about 0.8 % of the mass of the total composition; isothiazolinones in an amount of about 0.5 % to about 1.2% of the mass of the total composition; gentamicin sulphate in an amount of about 0.3% to about 0.6%» of the mass of the total composition; water dispersible anionic pre-polymerized Acrylic-styrene binder in an amount of about 6% to about 6.6% of the mass of the total composition; bottom ash of particle size above 45 microns in an amount of about 28% to about 32% of the mass of the total composition; silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about 32% to about 36%
  • the present invention provides a composition suitable as a crack filler in building construction which comprises demineralized water in an amount of about 22% to about 22.5% of mass of the total composition; acrylic polymer in an amount of about 1% to about 1.27 % of mass of the total composition; liquid ammonia in an amount of about 0.3 % to about 0.4 % of the mass of the total composition; isothiazolinones in an amount of about 0.1 % to about 1 % of the mass of the total composition; garsol in an amount of about 1 % to about 1 .2 % of the mass of the total composition; water dispersible anionic pre-polymerized Acrylic-styrene binder in an amount of about 12% to about 14% of the mass of the total composition; bottom ash of particle size above 45 microns in an amount of about 27% to about 29% of the mass of the total composition; and silica particle mixture with particle size in the range of 400 micron to 1000 micron in an amount of about 32% to about 33.5%
  • a process for manufacturing of said composition suitable for use in building construction comprises the following steps: soft water which is free from bacteria, a thickener, a pH stabilizer, a preservative, a coalescing agent and an anionic pre-polymerized binder are mixed in a stainless steel mixer at a speed of about 1200-1700 rpm and a temperature of about 10- 50°Cfor about 2-3 hrs. to obtain a first concentrate. Then appropriate amount of water, bottom ash, silica and stone grit are added to the first concentrate and the whole mixture is then mixed at a speed of about 400-800 rpm to obtain a homogeneous composition suitable for use in building construction.
  • At least one additive selected from a group of additives consisting a dispersing agent and a wax emulsion can also be incorporated in said composition.
  • the composition prepared in accordance with the present invention is in ready to use form hence no on site mixing of water and additives is required. It can be applied in conventional method using a spatula or directly applied from the spout or squeezed out to lay the material. Since said composition is self-curing, neither pre-wetting nor post curing with water is required.
  • the anionic pre-polymerized binder employed in said composition gets cured because of the air oxidation and forms reticulation network structure. Hence the pre- polymerized binder facilitates the curing process in said composition and results into the product having stronger bond strength.
  • the product cures with ageing, improving the bond strength as well as the water resistance.
  • the composition disclosed in accordance with the present invention is employed as a mortar, plaster/render, crack filler a repair mortar and grouting mortar and applied on clay bricks, fly ash bricks, aerated concrete blocks, cement blocks and on wet cement layer, RCC surfaces, conventionally plastered surfaces, asbestos surfaces and similar surfaces.
  • composition was then tested for tensile strength, compressive strength, shear strength, wall strength, water absorption, shrinkage, and temperature cycle and adhesion test.
  • composition prepared in accordance with abovementioned example is more suitable as an adhesive mortar as well as a grouting mortar. It has been observed that, the shelf life of the product is more than 120 days and pot life is more than 8 to 10 hrs. If the product is sealed back it can be used even after 10 to 15 days. The product performance improves with ageing.
  • composition is suitable as an adhesive mortar which shows better hardness and faster drying than the hardness of example- 1 due to the presence of styrene polymer.
  • Example 3
  • composition was then tested for tensile strength, compressive strength, shear strength, wall strength, water absorption, shrinkage, and temperature cycle and adhesion test.
  • the composition suited better as a plastering material and as a crack filler.
  • the material upon drying showed better water resistance than example- 1 , but was slightly brittle in nature. It showed good bond strength and dries faster.
  • composition was then tested for tensile strength, compressive strength, shear strength, wall strength, water absorption, shrinkage, and temperature cycle and adhesion test.
  • the composition was suitable as plaster and as crack filler.
  • the composition showed increased drying time and hence setting time was affected.
  • the material becomes flowy and difficult to be applied in desired thickness to function as desired for the purpose, and thus affects economics.
  • composition containing bottom ash with particle size at 60 to 100 microns tends to show better performance in terms of drying and setting time, resistance to water absorption and was better for bulk, can be used in lesser quantity than fly ash and suits economically.
  • composition was too thick and the spreadabilty was lowered.
  • shelf life was reduced and with time tendency to show separation of materials.
  • composition was then tested for tensile strength, compressive strength, shear strength, wall strength, water absorption, shrinkage, and temperature cycle and adhesion test.
  • Example 25 Similar procedure as described in example-2 was carried out without adding stone grit into the first concentrate. The whole mixture was then mixed at a speed of about 600 rpm to obtain a homogeneous mixture suitable as plaster and repair mortar having density of 1.14. The composition exhibited high spreadabilty, reduced water resistance than ex 20 but within the expected range and increased drying time.
  • Example 25 Similar procedure as described in example-2 was carried out without adding stone grit into the first concentrate. The whole mixture was then mixed at a speed of about 600 rpm to obtain a homogeneous mixture suitable as plaster and repair mortar having density of 1.14. The composition exhibited high spreadabilty, reduced water resistance than ex 20 but within the expected range and increased drying time. Example 25
  • the composition offered good resistance to water, easy to spread, improved hiding, colour was changed.
  • the composition had good strength, matched all the requirements, had higher viscosity, which reduces spread ability.
  • cellulosic fibers increased the viscosity and strength, but reduced spreadabilty and shelf life.
  • a mortar layer of 4 mm thickness was applied on one surface of a burnt clay brick.
  • Another clay brick was bonded to the burnt clay brick surface having the mortar layer.
  • the two bricks were placed on a table to maintain a cantilever position.
  • the two bricks were left for curing for test reports are for 28 days & 120 days without disturbing the mortar layer.
  • the tensile bonding strength was checked by hanging an initial weight to one end of the clay brick. This initial weight was increased until the bond between the two bricks broke. It was observed, though the bond survived the tensile bonding strength test, the clay brick broke.
  • a mortar of 4 mm thickness and dimensions of 25 mm x 25 mm was applied on one end of a wooden ply plate having dimensions of approximately 25 mm x 75 mm. Another wooden ply plate having same dimensions was placed on the mortar layer.
  • the assembly was allowed to cure for two days. After curing, the assembly was suspended in a vertical position from a rack on a spring balance provided with a hook attached to one of the wooden ply plate. An initial weight was hanged at the bottom of one of the wooden ply plate. This initial weight was increased at lower end of wooden ply plate until the joint between the hook and the wooden ply broke.
  • the mortar was tested as a building material in comparison with the conventional mortar.
  • the mortar was given to several masons, engineers, architects and building contractors, to build walls by using the mortar as an adhesive material for bonding the clay bricks, concrete blocks, fly ash bricks and the like.
  • the walls were hammered for demolition. Strenuous efforts were required to demolish the walls and breakage of blocks/ bricks was observed while the mortar bond remains intact.
  • Test 1 A mastic was made in a block having dimensions of 5cm. X 5cm. X 6 mm. The block was allowed to cure completely, followed by which it was immersed in water for 2 hrs. The block was then allowed to dry naturally for 2 hrs. This was repeated in cyclic pattern. The weight of the block before and after immersion was noted and the physical condition was observed. The difference in the weights indicates the absorption and loss of water. The physical condition of the block indicates the effects caused by the process. Test 2 -A mastic was applied in uniform thickness of 6 mm on a glass tile. Upon hard drying the mastic was dipped in water for 24 hrs. and the change in weight was noted which indicates the water absorbed by the mastic.
  • a mastic was made in a block having dimensions of 5cm X 5cm X 6mm and allowed to cure completely.
  • the block was subjected to temperatures up to 60 ° C in a lab oven and then cooled to temperatures as low as - 6° C.
  • the same procedure was repeated in a cyclic pattern to check the impact of temperature difference on the block.
  • the physical condition of the block remained unchanged even after the drastic temperature variations.
  • a mastic was applied in uniform thickness of 6 mm on a glass tile. The thickness of mastic along with glass thickness was noted. The same was measured upon hard drying to check the difference in the film thickness. Upon drying, negligible shrinkage was observed in the mastic.
  • a mastic was applied in uniform thickness of 6 mm on a glass tile. Upon drying, the mastic was checked for a tape test to determine its adhesion to the substrate. In the tape test, a cello tape was pressed on the mastic and then removed. It was observed that no mastic adhered to the cello tape proving that the adhesion of the mastic is excellent.
  • a mortar was prepared in accordance with the recipe of example-2. This mortar was subjected to the aforesaid tests like bonding strength , Shear Bonding, Wall Strength test, Water absorption test, Temperature cycle Test, Shrinkage test, Adhesion Test, compressive test and other physical properties like colour, viscosity , density, drying /setting time , solid content and pH, pot life, shelf life ,effects of acid ,alkali. The results are tabulated in the following table. TABLE 3
  • a plaster /render was prepared in accordance with the recipe of ex no 34. This plaster was subjected to the aforesaid tests like bonding strength , Shear Bonding, Wall Strength test, Water absorption test, Temperature cycle Test, Shrinkage test, Adhesion Test, compressive test and other physical properties like colour, viscosity , density, drying /setting time , solid content and pH, pot life, shelf life ,effects of acid ,alkali. The results are tabulated in the following table. TABLE 4
  • a crack filler was prepared in accordance with the recipe of ex no 42 :
  • a grouting mortar was prepared in accordance with the recipe of example- 37. This grouting mortar was subjected to the aforesaid tests like bonding strength , Shear Bonding, Wall Strength test, Water absorption test, Temperature cycle Test, Shrinkage test, Adhesion Test, compressive test and other physical properties like colour, viscosity , density, drying /setting time , solid content and pH, pot life, shelf life ,effects of acid , alkali. The results are tabulated in the following table. TABLE 6
  • a repair mortar was prepared in accordance with the recipe of example-39 This repair mortar was subjected to the aforesaid tests like bonding strength, Shear Bonding, Wall Strength test, Water absorption test, Temperature cycle Test, Shrinkage test, Adhesion Test, compressive test and other physical properties like colour, viscosity, density, drying /setting time, solid content and pH, pot life, shelf life, effects of acid, alkali. The results are tabulated in the following table. TABLE 7
  • compositions were made by employing the recipe of conventional mortar containing Portland cement and sand in ratio of 1 :6. Essential amount of water was added to make the composition applicable as a brick laying mortar. The compositions were subjected to the aforesaid bonding strength, Shear Bonding, Wall Strength test, Water absorption test, Temperature cycle Test, Shrinkage test, Adhesion Test and compressive test as well as other physical properties , such as colour ,viscosity , density, drying /setting time , solid content and pH, pot life, shelf life , effects of acid , alkali.
  • compositions were made of varying proportions within the range according to PCT application and the compositions were subjected to the above tests
  • compositions were made in accordance with examples 1 to 7 and 9 to 42 of the present invention and subjected to the above tests.
  • composition disclosed in accordance with the present invention offers many advantages over the composition prepared in conventional manner and composition prepared in accordance with the PCT application cited above.
  • the density of the composition of the present invention is almost half the conventional material and little more than the composition disclosed in our PCT application, thus the material is almost 50 % lighter than the conventional material, which eases the application reducing the labour effort.
  • the speed of construction is increased by almost 30 to 40 %, labour requirement is less as no help is needed in material handling on site, no time is required for pre wetting, post curing and cleaning.
  • the bond strength is about 3 to 5 times greater than the conventional material at 28 days and increases with age.
  • the shear strength is 10 to 12 times more than conventional material and increases with age. 4.
  • the compressive strength is 2.5 to 3 times greater than the conventional material.
  • the drying time is almost the same or slightly greater than the conventional material.
  • the drying time of the composition of the present invention is inversely proportional to temperature and directly proportional to humidity.
  • the pH is alkaline and matches the currently known materials which make it similar in performance to acid and alkali resistant.
  • shelf life is not applicable to the conventional material as it is on site preparation, while the shelf life of the composition of the present invention is much better than the composition according to the PCT application.
  • the pot life is 5 to 7 times better than the conventional mortar.
  • the composition of the present invention can be reused even after 15 to 20 days by repacking it .This is not at all possible with the conventional material. This enables the reusing of the material and minimizes or almost eliminates wastage.
  • composition of the present invention shows flexibility due to the presence of polymers while the conventional material is brittle upon drying.
  • the conventional material debonds and cracks if not cured with sufficient amount of : water, while the composition of the present invention does not need any water curing but sets with air drying.
  • the water mixed in the composition is used for hydration to form calcium hydrate sulphate, which gives strength to the material.
  • the composition of the present invention uses water only as a carrier medium.
  • a composition suitable for use in building construction disclosed in accordance with the present invention is designed to offer total replacement of the conventional Portland cement based mortars, plaster/render, grouting mortar and crack filing material. Furthermore, the invention also provides a process for producing said composition which is a cool green process since the process in accordance with the present invention does not use Portland cement hence there is no carbon dioxide releasement which supports in preventing global warming.
  • the composition of the present invention eliminates one of the major pollutants of the environment like bottom ash and/or fly ash, hence the invention offers an environmental friendly and eco-friendly product which is non-hazardous to the applicators and end-users. The composition needs minimal efforts to apply and creates excellent bonding as compared to the conventional compositions employed in the building construction.
  • composition disclosed in accordance with the present invention is ready to use, wet mix adhesive and needs very minimal amount of water for workability. Also, since there is no wastage of material during the application, the construction site remains clean. Also, the product is self curing and therefore, on application it does not require pre wetting and post curing with water. Thus, the entire water in the product is evaporated and returns to environment which saves almost 100% water. Additionally, the composition adds value to the construction by providing a composition which is crack resistant and therefore limits seepage of water or moisture. Thus, the composition limits the growth of fungus which otherwise causes damage to the construction. The composition of the present invention provides better weather resistance thus enhances the life of the construction. On scraping, the walls constructed using said composition; the material can be easily recycled or disposed of safely in a land fill.
  • composition employed in the building construction is mainly based on Portland cement, sand and water in which all the ingredients are mixed on-site.
  • the composition prepared in accordance with the present invention is in ready to use form and no pre-wetting and post curing with water is required hence no extra supervision is required which not only saves the time and labour but also water.

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

Abstract

La présente invention concerne une composition conçue pour être utilisée dans la construction d'un bâtiment. Ladite composition comprend de l'eau, un épaississeur, un agent de stabilisation de pH, un agent de préservation, un agent de coalescence, un liant anionique prépolymérisé, du mâchefer, un mélange de particules de silice, de la pierre concassée, une matière de remplissage et une matière de charge. L'invention concerne en outre un procédé de production de la composition. La composition de l'invention est écologique, exempte de ciment Portland, prête à utiliser sous forme de mélange humide, avec une vie en pot et une stabilité en stockage étendues. La composition préparée selon la présente invention est utilisée en tant que mortier, plâtre/enduit, mortier de réparation, mortier de remplissage et enduit antifissures.
PCT/IN2010/000024 2009-11-12 2010-01-15 Composition conçue pour la construction de bâtiments WO2011058574A2 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/IN2010/000024 WO2011058574A2 (fr) 2009-11-12 2010-01-15 Composition conçue pour la construction de bâtiments
CH00444/11A CH702564B1 (it) 2010-01-15 2010-01-15 Una composizione adatta all'uso per la costruzione edilizia.
AU2010100046A AU2010100046A4 (en) 2009-11-12 2010-01-18 A composition suitable for use in building construction

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EP3230227A4 (fr) * 2014-12-11 2018-12-05 Henry Company LLC Produits résistant à l'eau contenant une émulsion de cire
FR3100251A1 (fr) * 2019-09-04 2021-03-05 Pouzzolanes Des Domes Materiau composite de revetement de surface et son procede de realisation
CN112551976A (zh) * 2020-12-07 2021-03-26 绵竹市铸诚混凝土有限公司 一种高强度防锈混凝土及其制备工艺
IT201900023172A1 (it) * 2019-12-06 2021-06-06 Sanfilippo Acqua E Materia S R L Materiale composito per realizzare coperture particolarmente calpestabili e processo per realizzarlo
CN113031678A (zh) * 2021-02-26 2021-06-25 郑州铁路职业技术学院 一种生物质物联网铁路运输集装箱
CN113321441A (zh) * 2021-06-28 2021-08-31 青岛理工大学 硅烷复合乳液作为抗裂增强剂的应用
CN113666663A (zh) * 2021-10-20 2021-11-19 佛山市天工嘉荟文化科技有限公司 一种大面积补配陶瓷缺损用料及古陶瓷修复工艺
GB2619366A (en) * 2022-05-31 2023-12-06 Newall Plant Ltd Building Materials and Method of Production thereof

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WO2012073258A2 (fr) * 2010-11-30 2012-06-07 Pradeep Vasant Joshi Composition utilisable dans la construction de bâtiments
CN113354345B (zh) * 2021-07-09 2022-07-26 吉林建筑大学 一种分步法制备地铁混凝土的方法

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WO2005105701A1 (fr) * 2004-04-27 2005-11-10 Hercules Incorporated Composes de joint utilisant des epaissisants prepares a partir linters de coton brut

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WO2002012144A2 (fr) * 2000-08-04 2002-02-14 Lafarge Platres Procede, assemblage et revetement supplementaire relatifs a la fabrication d'ouvrages interieurs
US20050056187A1 (en) * 2003-09-15 2005-03-17 Podlas Thomas J. Tape joint compounds with CMC thickener system
WO2005105701A1 (fr) * 2004-04-27 2005-11-10 Hercules Incorporated Composes de joint utilisant des epaissisants prepares a partir linters de coton brut

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3230227A4 (fr) * 2014-12-11 2018-12-05 Henry Company LLC Produits résistant à l'eau contenant une émulsion de cire
FR3100251A1 (fr) * 2019-09-04 2021-03-05 Pouzzolanes Des Domes Materiau composite de revetement de surface et son procede de realisation
IT201900023172A1 (it) * 2019-12-06 2021-06-06 Sanfilippo Acqua E Materia S R L Materiale composito per realizzare coperture particolarmente calpestabili e processo per realizzarlo
CN112551976A (zh) * 2020-12-07 2021-03-26 绵竹市铸诚混凝土有限公司 一种高强度防锈混凝土及其制备工艺
CN113031678A (zh) * 2021-02-26 2021-06-25 郑州铁路职业技术学院 一种生物质物联网铁路运输集装箱
CN113031678B (zh) * 2021-02-26 2022-05-06 郑州铁路职业技术学院 一种生物质物联网铁路运输集装箱
CN113321441A (zh) * 2021-06-28 2021-08-31 青岛理工大学 硅烷复合乳液作为抗裂增强剂的应用
CN113321441B (zh) * 2021-06-28 2022-06-14 青岛理工大学 硅烷复合乳液作为抗裂增强剂的应用
CN113666663A (zh) * 2021-10-20 2021-11-19 佛山市天工嘉荟文化科技有限公司 一种大面积补配陶瓷缺损用料及古陶瓷修复工艺
CN113666663B (zh) * 2021-10-20 2021-12-21 佛山市天工嘉荟文化科技有限公司 一种大面积补配陶瓷缺损用料及古陶瓷修复工艺
GB2619366A (en) * 2022-05-31 2023-12-06 Newall Plant Ltd Building Materials and Method of Production thereof

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