WO2011152559A1 - 人工石材およびその製造方法 - Google Patents
人工石材およびその製造方法 Download PDFInfo
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- WO2011152559A1 WO2011152559A1 PCT/JP2011/063089 JP2011063089W WO2011152559A1 WO 2011152559 A1 WO2011152559 A1 WO 2011152559A1 JP 2011063089 W JP2011063089 W JP 2011063089W WO 2011152559 A1 WO2011152559 A1 WO 2011152559A1
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- artificial stone
- mud
- slag
- steelmaking slag
- blast furnace
- Prior art date
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- 239000002969 artificial stone Substances 0.000 title claims abstract description 38
- 238000004519 manufacturing process Methods 0.000 title claims description 22
- 239000002893 slag Substances 0.000 claims abstract description 103
- 239000000463 material Substances 0.000 claims abstract description 96
- 238000009628 steelmaking Methods 0.000 claims abstract description 53
- 239000011230 binding agent Substances 0.000 claims abstract description 31
- 238000002156 mixing Methods 0.000 claims abstract description 10
- 239000000203 mixture Substances 0.000 claims abstract description 6
- 239000000843 powder Substances 0.000 claims description 40
- 239000002689 soil Substances 0.000 claims description 31
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 21
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 10
- 239000011398 Portland cement Substances 0.000 claims description 10
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 10
- 230000032683 aging Effects 0.000 claims description 10
- 239000010881 fly ash Substances 0.000 claims description 10
- 239000004571 lime Substances 0.000 claims description 10
- 239000011400 blast furnace cement Substances 0.000 claims description 9
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 claims description 7
- 239000000920 calcium hydroxide Substances 0.000 claims description 7
- 235000011116 calcium hydroxide Nutrition 0.000 claims description 7
- 229910001861 calcium hydroxide Inorganic materials 0.000 claims description 7
- 238000004898 kneading Methods 0.000 claims description 6
- 238000000227 grinding Methods 0.000 claims description 5
- 230000000887 hydrating effect Effects 0.000 claims description 4
- 239000004575 stone Substances 0.000 abstract description 32
- 239000004567 concrete Substances 0.000 abstract description 11
- 238000006703 hydration reaction Methods 0.000 abstract description 6
- 230000036571 hydration Effects 0.000 abstract description 5
- 239000013049 sediment Substances 0.000 abstract 1
- 239000011499 joint compound Substances 0.000 description 39
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 36
- 239000004927 clay Substances 0.000 description 30
- 239000003513 alkali Substances 0.000 description 18
- 239000000292 calcium oxide Substances 0.000 description 18
- 235000012255 calcium oxide Nutrition 0.000 description 18
- 238000000034 method Methods 0.000 description 14
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- 229910004298 SiO 2 Inorganic materials 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 229910001424 calcium ion Inorganic materials 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- 238000013329 compounding Methods 0.000 description 2
- 238000005261 decarburization Methods 0.000 description 2
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- 239000013535 sea water Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/14—Waste materials; Refuse from metallurgical processes
-
- 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
- C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
- C04B22/06—Oxides, Hydroxides
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/08—Slag cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B7/00—Hydraulic cements
- C04B7/14—Cements containing slag
- C04B7/147—Metallurgical slag
- C04B7/153—Mixtures thereof with other inorganic cementitious materials or other activators
- C04B7/17—Mixtures thereof with other inorganic cementitious materials or other activators with calcium oxide containing activators
- C04B7/19—Portland cements
-
- 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 an artificial stone material obtained by solidifying mud such as dredged soil with a binder and a method for producing the same.
- Soft mud represented by dredged soil, is generated with the construction of channel dredging and various civil engineering works.
- those that are useful as civil engineering materials such as sand can be used as they are for shallow field construction and backfilling, but in the case of mud with a high ratio of silt, there are many things that contain water In addition, because it can hardly be expected as strength as soil, it often becomes waste.
- Various techniques have been proposed and implemented for effective use of mud. The most representative one is a technique for improving the characteristics of soil and using it in the same way as high-quality soil. For example, “Stable treatment method for soft ground with lime” by the Japan Lime Association (Kashima Publishing Co., Ltd.) shows various techniques for improving the properties of the ground by adding cement and lime to mud.
- Patent Document 1 discloses a technique for improving strength by mixing steel slag with clay, and in this technique, the CaO content of steel slag and Si, Al, etc. of the clay are mainly used. The strength of clay is improved by pozzolanic reaction.
- Patent Document 2 discloses a technique for performing solidification treatment (improvement of strength) by adding converter slag containing free CaO and blast furnace cement to soft soil.
- these methods are improvement of characteristics as a soil material, and although the strength is developed, it is limited to the use as soil.
- Patent Document 3 discloses a method of obtaining a block material (solidified body) by mixing and solidifying a solidified material made of blast furnace slag, quicklime, fly ash or the like into clay.
- a block material is produced by adding about 40 to 60 (parts by mass) of a solidifying material to 100 parts (parts by mass) of the clay including moisture, and solidifying the kneaded material.
- the method of Patent Document 3 describes that a lightweight block material having an apparent density of about 1.45 to 1.65 g / cm 3 can be manufactured.
- the intensity of the block material obtained by the method of Patent Document 3 is on average at a 6N / mm 2 approximately, only about 8N / mm 2 at most.
- it In order to use it as a substitute for stone or concrete material, it must have a strength (9.8 N / mm 2 or more) equal to or higher than the semi-hard stone specified in JIS-A-5006: 1995 (split stone).
- the strength of the block material obtained in Patent Document 3 is the level of the lowest quality soft stone (less than 9.8 N / mm 2 ), which is considerably higher than the improvement level of the soil material, but stone material and concrete material It is not strong enough to be used for various purposes as an alternative to the above.
- the object of the present invention is to solve the problems of the prior art as described above, and to use a large amount of mud such as dredged material as a material, and has a strength higher than that of semi-hard stone and lighter than concrete. To provide stone. Moreover, the other object of this invention is to provide the manufacturing method which can manufacture such an artificial stone material stably.
- a hydrated cured product obtained by hydrating and curing a kneaded mixture of mud, binder, and granular steelmaking slag, and having a mass per unit volume of 2000 to 2200 kg / m 3 A lightweight artificial stone characterized by being.
- the lightweight artificial stone material according to [1], wherein the uniaxial compressive strength after curing for 28 days is 15 N / mm 2 or more.
- the binder contains 80 to 95% by mass of blast furnace slag fine powder, and the balance is ordinary Portland cement, lime powder, slaked lime, or blast furnace cement.
- the binder contains a total of 80 to 95% by mass of fine blast furnace slag powder and fly ash, with the balance being ordinary Portland cement, lime powder, slaked lime,
- the steelmaking slag is aged with a slag containing 0.5% by mass or more of free CaO to a powdering rate of 2.5% or less.
- Lightweight artificial stone characterized by steelmaking slag.
- a method for producing a lightweight artificial stone material [7] A method for producing a lightweight artificial stone material according to [6] above, wherein the dredged soil generated by dredging work is stored as mud.
- the artificial stone material of the present invention can use a large amount of mud such as dredged material, it can be used effectively. Moreover, since it has a strength equal to or higher than that of semi-hard stone and is lighter than concrete, it is particularly useful for stone materials that require strength, durability, and lightness. Moreover, according to the manufacturing method of this invention, such an artificial stone material can be manufactured stably.
- FIG. 1 shows a hydrated hardened body obtained from a mixed material composed of clay, binder (blast furnace slag fine powder + alkali stimulant), and aggregates of natural crushed stone and natural sand. It is a graph which shows the relationship between a ratio and the mass per unit volume of a hydration hardening body.
- FIG. 2 shows a hydrated hardened body obtained from a mixed material composed of clay, binder (fine powder of blast furnace slag + alkali stimulant) and aggregate, and aggregated natural crushed stone / natural sand and steelmaking slag. It is a graph which shows the intensity
- FIG. 3 is an explanatory diagram showing an embodiment in the case where the dredged soil stored in the dredging yard is used as the mud in the present invention.
- the artificial stone material of the present invention is a hydrated hardened body obtained by hydrating and curing a kneaded mixture of mud, a binder and granular steelmaking slag, and has a mass per unit volume of 2000 to 2200 kg / it is obtained by the m 3.
- the inventors of the present invention pay attention to the light weight of the clay, and study the blending conditions for expressing the strength of the hydrated cured body (hereinafter sometimes referred to as “solidified body”) that uses a large amount of the clay as a material. did.
- the inventors manufactured a solidified body in which only blast furnace slag fine powder and an alkaline stimulant were added as a binder to the clay, but only a brittle solidified body having a small specific gravity and easily cracked by impact was obtained. It was. In particular, when the proportion of clay was increased, the whole became a lump of powdery material, which became brittle and weak against wear and the like, and because it was too light, stability as a stone could not be expected.
- Fig. 1 shows the ratio and solidification of the clay in the mixed material obtained from the mixed material consisting of the clay, binder (blast furnace slag fine powder + alkali stimulant), and aggregated natural crushed stone and natural sand. The relationship with the mass per unit volume of the body is shown.
- a solidified body artificial stone
- the amount of dredged soil is not sufficient from the viewpoint of effective utilization of dredged soil.
- the present inventors further studied measures for solving the above points, examined some aggregates having a large specific gravity, and repeated trial production.
- the strength of the solidified body tends to be slightly lower than the strength assumed from the added blast furnace slag fine powder and the alkali stimulant. That is, it was found that even when a material (aggregate) having a large specific gravity was simply added, the strength was not exhibited as expected. Therefore, as a result of studying the cause of this, the present inventors have found that the clay has an action of adsorbing alkali components, so that it inhibits the pozzolanic reaction, which is a basic reaction of solidification of cement and blast furnace slag fine powder. It was found that there was a possibility.
- the solidified body using steelmaking slag as the aggregate exhibits higher strength than the solidified body using natural crushed stone and natural sand as the aggregate.
- the reason for this is not necessarily clear, but can be considered as follows. That is, since the steelmaking slag is an oxide containing a large amount of Ca, when the steelmaking slag comes into contact with water, Ca ions and OH ions are supplied. As a result of these ions mitigating the reaction-inhibiting factors caused by the clay as described above, it is considered that a solid body with high strength can be obtained. Therefore, by mixing and mixing hydrated powdered steelmaking slag and binder to the mud, the water has an appropriate specific gravity and high strength while using a large amount of mud. A Japanese cured product can be obtained.
- the mass per unit volume of the artificial stone material is less than 2000 kg / m 3, it is lower than the specific gravity that is the standard of semi-hard stone described in JIS-A-5006: 1995. This is suitable for application to soft ground. However, the stability with respect to the role that the artificial stone material should originally play, such as being easily washed away by waves, is reduced. On the other hand, if it exceeds 2200 kg / m 3 , the average weight level of the quasi-hard stone is obtained, and there is no significant difference from the case of using a normal stone material when applied to an application where a light weight is desired. In addition, it is difficult to secure a sufficient amount of dredged material.
- the mass per unit volume is set to 2000 to 2200 kg / m 3 .
- the strength of the artificial stone material may be equal to or higher than the quasi-hard stone specified by JIS-A-5006: 1995, that is, the uniaxial compressive strength after curing for 28 days may be 9.8 N / mm 2 or higher.
- the strength of natural stone is stable, but in the case of a solidified body, variation or the like occurs depending on the blending conditions. Therefore, the uniaxial compressive strength after curing for 28 days is more preferably 15 N / mm 2 or more.
- the mud used in the present invention is typically dredged, but other examples include mud generated from excavation work and construction sludge.
- the muddy soil generally refers to a material that cannot be piled up and exhibits fluidity that prevents people from walking on it.
- the cone index defined by JIS-A-1228: 2009 (cone index test method for compacted soil) is 200 N / mm 2 or less.
- the mud soil typified by dredged soil has a greater effect of adsorbing ions (alkalis) as the silt content increases, and the prior art makes it difficult to obtain a solid body having an appropriate strength, so that the present invention is particularly useful.
- the present invention is particularly useful when a mud soil containing 70 vol% or more of soil particles (silt content) having a particle size of 0.075 mm or less is targeted.
- mud can be used in the mixed material at a ratio of 40% by volume or more.
- the binder examples include blast furnace slag fine powder, blast furnace slag fine powder to which an alkali stimulant is added, blast furnace cement, ordinary portland cement, and the like, and one or more of these can be used.
- blast furnace slag fine powder blast furnace cement, ordinary portland cement, and the like
- the hydration reaction of the blast furnace slag fine powder can be promoted, and the strength of the solidified body can be ensured.
- the pH increase when the solidified body is immersed in water becomes larger than when an alkali stimulant is used together with the blast furnace slag fine powder. Therefore, when considering the load on the surrounding environment, it is suitable to use an alkali stimulant together with the blast furnace slag fine powder.
- the alkali stimulating agent for example, one or more kinds of lime powder, slaked lime, ordinary Portland cement, blast furnace cement and the like can be used. In this case, it is preferable that 80 to 95% by mass of blast furnace slag fine powder is contained, and the balance is one or more selected from lime powder, slaked lime, ordinary Portland cement, and blast furnace cement.
- an alkali stimulant is used together with the blast furnace slag fine powder as a binder, if the proportion of the blast furnace slag fine powder is 80% by mass or more, an excess alkali component does not remain in the solidified body. Therefore, when using a solidified body in the sea, the alkali load with respect to seawater environment is small. It is also economically advantageous.
- the type of steelmaking slag that is an aggregate is not particularly limited, but includes hot metal pretreatment slag (dephosphorization slag, desiliconization slag, desulfurization slag, etc.), converter decarburization slag, electric furnace slag, etc.
- hot metal pretreatment slag dephosphorization slag, desiliconization slag, desulfurization slag, etc.
- converter decarburization slag preferably has a maximum particle size of 25 mm or less. Larger particle sizes can also be used.
- steelmaking slag contains free CaO, and even when stabilized by steam aging or the like, if the slag particle size is large, there is a high possibility that free CaO will remain inside, and it will be used for a long time. When this occurs, it may expand and become a cause of defects.
- the ratio of particles having a particle size of 0.15 mm or more may be 80% by mass or more of the entire steelmaking slag. More desirable.
- the basicity (CaO / SiO 2 ) is preferably about 2.0 to 5.0.
- generated by the steelmaking process contains 0.5 mass% or more of free CaO
- free CaO often remains. Free CaO is quickly converted into Ca (OH) 2 upon contact with water, and has the advantage of being easily ionized and involved in the reaction.
- the free CaO remaining inside the slag particles expands when contacted with the penetrating water, cracks occur inside the particles, and there is a possibility that defects occur inside the solidified body.
- the mineral phase constituting the solid particles of mud is completely different depending on the dredging area and occurrence history. Therefore, depending on the type of clay, the Ca component supplied from the steelmaking slag may become excessive, and there may be cases where the reactivity of the kneaded product becomes unstable and the pH of water in contact with the hardened body increases.
- fly ash is mainly composed of amorphous SiO 2 and Al 2 O 3 , it can be expected that a pozzolanic reaction occurs more rapidly than an crystalline material when an excessive alkali content is generated.
- fly ash is added excessively, the amount of Ca in the binder becomes too small, and the stability of the reaction of the original clay, steelmaking slag, and binder may be impaired.
- the compounding quantity shall be 30 mass% or less with respect to blast furnace slag fine powder.
- the total content of the blast furnace slag fine powder and fly ash is set to 80 to 95% by mass for the same reason as described above, and the balance is ordinary. It is preferable that the fly ash is 30% by mass or less with respect to the blast furnace slag fine powder, which is composed of one or more selected from Portland cement, lime powder, slaked lime, and blast furnace cement.
- the artificial stone material of the present invention can use a large amount of clay, and can also effectively use steelmaking slag, which is an industrial byproduct, and has a strength higher than that of semi-hard stone. And it has the performance of being lighter than concrete. For this reason, it is very useful as a stone material installed on soft ground or the like.
- a steelmaking slag which is mud, a binder and an aggregate is blended, and a mixed material to which water is added as necessary is kneaded. Get.
- the purpose of the present invention is to effectively use mud represented by dredged soil, and therefore it is preferable that the proportion of mud in the mixed material is as large as possible. Therefore, mud, binder and powder in the mixed material are preferable.
- the ratio of the mud to the granular steelmaking slag (the ratio including the water originally contained in the mud) is preferably 40% by volume or more.
- the ratio of mud is 60% by volume or less, the mass per unit volume can be easily set to 2000 kg / m 3 or more, and the aggregate ratio does not decrease, so the solidified body does not become brittle. Ensuring sufficient durability is facilitated. For this reason, the ratio of the mud to the mud, the binder and the granular steelmaking slag in the mixed material is preferably 40 to 60% by volume.
- More preferable production conditions include mud, a binder and a granular steelmaking slag having a water content ratio of 180 to 250%, and the ratio of the mud to the mud, the binder and the granular steelmaking slag is 40 to 60% by volume.
- a mixed material having a steelmaking slag content of 750 kg / m 3 or more per volume of the mixed material is kneaded, and the kneaded product is hydrated and cured.
- the hydrated cured product has a mass per unit volume of 2000 to 2200 kg / m 3 , a uniaxial compressive strength after curing for 28 days of 15 N / mm 2 or more, and has little variation in characteristics. Can be manufactured stably.
- the kneaded material When kneading a mixed material having a ratio of kneaded clay of 50% by volume and a steelmaking slag content of 1000 kg / m 3 , the kneaded material is hydrated and cured to obtain a solidified body.
- the properties of the slump and solidified material used were investigated. The results are shown in Table 1.
- strength of a solidified body is the uniaxial compressive strength after curing for 28 days measured by the same method as an Example. According to Table 1, when the water content ratio of the clay is less than 180%, the solidified material has sufficient characteristics, but the mixed material has no fluidity (no slump), and industrial production is difficult. Even if it can be manufactured, the variation in characteristics becomes large.
- the moisture content of the clay is 240%, the strength starts to decrease, and when 260%, the strength is greatly decreased. Therefore, the moisture content of the clay is preferably 180 to 250%, more preferably 240% or less.
- the steelmaking slag needs to be blended in a certain amount or more in the mixed material from the viewpoint of the effect of supplying Ca ions and OH ions as described above, and also to secure the volume stability of the solidified body. It is preferable to mix 750 kg / m 3 or more per mixed material volume, and more preferably 1000 kg / m 3 or more. However, if the amount of steelmaking slag is 1450 kg / m 3 or less, the unit volume mass of the solidified body does not become excessive, and it is not necessary to reduce the weight by using a large amount of water, and sufficient strength can be obtained. Therefore, the amount of steelmaking slag is preferably 1450 kg / m 3 or less.
- a normal fresh concrete kneading facility may be used, but it may be carried out in a yard such as outdoors using a heavy machine for civil engineering work such as an excavator.
- a heavy machine for civil engineering work such as an excavator.
- it may be poured into an appropriate mold and solidified and cured (hydration hardening), or it may be cast in a layer on the yard such as outdoors to solidify and cure (hydration hardening). You may let them.
- the period of solidification / curing is until a target compressive strength is obtained, and is generally about 7 days or more.
- the obtained stone is crushed to an appropriate size as necessary.
- This crushing treatment may be performed using a crusher, and when the kneaded material is placed in layers in the yard as described above, the solidified body of the yard is roughly crushed with a breaker, and then crushed. You may crush with a machine.
- the solidified body (lumps) subjected to the crushing process is classified with a sieve to obtain a chunk of a predetermined size. For example, when used as a submerged dike material, a lump having a size of about 150 to 500 mm is obtained.
- the dredged soil generated by dredging works varies in water content depending on the dredging location.
- marine products such as seaweed and oysters
- contamination of seawater due to dredging work may affect the marine products.
- dredging works are not possible throughout the year, and there are restrictions on the construction time (seasonality).
- FIG. 3 shows an embodiment of the present invention using a dredging site, and dredged soil generated by dredging work is stored in the dredging site.
- the form and structure of the dredging yard is arbitrary, but, for example, it may be a structure in which earth and sand, slag, etc. are stacked in a yard to form an annular bank, and dredged soil is stored inside.
- the dredged soil generated during dredging work is transported to the dredging yard and stored, regardless of its water content and other properties. From the dredging site, it is appropriately supplied as mud in the solidified body (artificial stone) manufacturing process, and a lightweight artificial stone material is obtained by the manufacturing method described above.
- Table 2 and blended materials in compounding conditions shown in Table 3 (mixed for 5 minutes at 0.75 m 3 kneading plant, discharged after a predetermined time has elapsed) kneading, diameter 100 mm ⁇ a kneaded product of this mixed material
- a solid body artificial stone material was produced by molding into a mold having a height of 200 mm and solidifying. The dredged soil used was 90% by volume of silt collected from the bottom of the Seto Inland Sea, and water was adjusted as necessary.
- the solidified bodies of the examples of the present invention have an appropriate unit volume mass (2000 to 2200 kg / m 3 ) and high strength.
- the solidified body of Comparative Example No. 33 has a unit volume mass because the moisture content of the clay is too low, the amount of steelmaking slag used is too large, the proportion of clay is too high, and the steelmaking slag is not used. Is inappropriate.
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Abstract
Description
泥土を有効利用するために、従来から様々な技術が提案、実施されている。その最も代表的なものが、土としての特性を改善し、良質な土と同じように利用するための技術である。例えば、日本石灰協会による「石灰による軟弱地盤の安定処理工法」(鹿島出版会)では、セメントや石灰を泥土に添加して、地盤としての特性を改善する様々な技術が示されている。
しかしながら、これらの方法は土質材料としての特性改善であり、強度が発現するとはいえ、あくまでも土としての用途に限定されるものである。
また、本発明の他の目的は、そのような人工石材を安定して製造することができる製造方法を提供することにある。
本発明はこのような知見に基づきなされたもので、以下を要旨とするものである。
[1]泥土、結合材および粉粒状の製鋼スラグを含む混合材料の混練物を水和硬化させて得られた水和硬化体であって、単位容積当たりの質量が2000~2200kg/m3であることを特徴とする軽量人工石材。
[3]上記[1]または[2]の軽量人工石材において、結合材が、高炉スラグ微粉末を80~95質量%含有し、残部が普通ポルトランドセメント、石灰粉、消石灰、高炉セメントの中から選ばれる1種以上であることを特徴とする軽量人工石材。
[4]上記[1]または[2]の軽量人工石材において、結合材が、高炉スラグ微粉末とフライアッシュを合計で80~95質量%含有し、残部が普通ポルトランドセメント、石灰粉、消石灰、高炉セメントの中から選ばれる1種以上であり、フライアッシュが高炉スラグ微粉末の30質量%以下であることを特徴とする軽量人工石材。
[6]上記[1]~[5]のいずれかの軽量人工石材を製造する方法であって、含水比が180~250%である泥土、結合材および粉粒状の製鋼スラグを含み、泥土、結合材および粉粒状の製鋼スラグに対する泥土の割合が40~55容積%、製鋼スラグの配合量が混合材料体積当たり750kg/m3以上である混合材料を混練し、該混練物を水和硬化させることを特徴とする軽量人工石材の製造方法。
[7]上記[6]の製造方法において、浚渫工事で発生した浚渫土であって、浚渫土置場に貯泥された浚渫土を泥土として用いることを特徴とする軽量人工石材の製造方法。
本発明者らは、浚渫土の軽量性に着目するとともに、材料として浚渫土を多量に用いる水和硬化体(以下、「固化体」という場合がある。)の強度を発現させる配合条件を検討した。まず、本発明者らは、浚渫土に結合材として、高炉スラグ微粉末及びアルカリ刺激剤だけを添加した固化体を製造したが、比重が小さくしかも衝撃で割れ易い、脆い固化体しか得られなかった。特に浚渫土の割合が多くなると、全体が粉状物質の塊となり、脆くなるうえに磨耗等にも弱くなり、また、軽くすぎるために石材としての安定性等も期待できないことが判った。
したがって、泥土に対して粉粒状の製鋼スラグと結合材を配合した混合材料を混練して水和硬化させることにより、泥土を多量に使用しつつ、適度な比重を有し且つ高い強度を有する水和硬化体を得ることができる。
また、人工石材の強度は、JIS−A−5006:1995で規定する準硬石相当以上であること、すなわち28日養生後の一軸圧縮強度で9.8N/mm2以上であればよい。また、天然石材は強度が安定しているが、固化体の場合には配合条件によってバラツキなどが発生するため、28日養生後の一軸圧縮強度で15N/mm2以上であることがより好ましい。
浚渫土に代表される泥土は、シルト分が多いほどそのイオン(アルカリ分)吸着効果が大きくなり、従来技術では適正な強度の固化体が得られにくくなるため、本発明が特に有用である。具体的には、本発明は、粒径0.075mm以下の土粒子(シルト分)を70容積%以上含有するような泥土を対象とする場合に、特に有用であると言える。
後述するように、泥土は混合材料中で40容積%以上の割合で使用することができる。
また、天然資材をできるだけ使用せずに環境負荷を軽減するという観点、さらには固化体の強度確保および製造コストの観点からは、結合材として、高炉スラグ微粉末にアルカリ刺激剤を添加したものが望ましい。結合材として、高炉スラグ微粉末とともにアルカリ刺激剤を用いることにより、アルカリ環境を作り出すことで、高炉スラグ微粉末の水硬性を発揮させることができる。つまり、高炉スラグ微粉末の水和反応を促進し、固化体の強度を確保することができる。また、普通ポルトランドセメントを結合材に使用した場合には、固化体を水に浸漬したときのpH上昇が、高炉スラグ微粉末とともにアルカリ刺激剤を使用した場合に較べて大きくなる。したがって、周辺環境への負荷を考えた場合には、高炉スラグ微粉末とともにアルカリ刺激剤を用いることが適している。
したがって、結合材として高炉スラグ微粉末とともにアルカリ刺激剤を用いる場合には、さきに述べたと同様の理由から、高炉スラグ微粉末とフライアッシュの合計含有量を80~95質量%とし、残部が普通ポルトランドセメント、石灰粉、消石灰、高炉セメントの中から選ばれる1種以上からなり、且つフライアッシュを高炉スラグ微粉末に対して30質量%以下とすることが好ましい。
本発明の人工石材の製造方法では、泥土、結合材および骨材である製鋼スラグを配合し、必要に応じて水を添加した混合材料を混練し、この混練物を水和硬化させて人工石材を得る。
本発明は、浚渫土に代表される泥土を有効利用することが目的であるので、混合材料中の泥土の割合が可能な限り多いことが好ましく、このため混合材料中の泥土、結合材および粉粒状の製鋼スラグに対する泥土の割合(元々泥土に含まれている水分を含む割合)は40容積%以上が好ましい。一方、泥土の割合が60容積%以下であれば、単位容積当たりの質量を2000kg/m3以上とすることが容易となり、また、骨材の比率が低くならないため、固化体が脆くならず、十分な耐久性の確保が容易になる。このため、混合材料中の泥土、結合材および粉粒状の製鋼スラグに対する泥土の割合は40~60容積%が好ましい。
このような好ましい製造条件によれば、単位容積当たりの質量が2000~2200kg/m3、28日養生後の一軸圧縮強度が15N/mm2以上であり、しかも特性のバラツキが少ない水和硬化体を安定して製造することができる。
混練物を固化させるには、例えば、適当な型枠に流し込んで固化・養生(水和硬化)させてもよいし、屋外などのヤードに層状に打設して固化・養生(水和硬化)させてもよい。特に、石材を大量に製造する場合には、ヤードに層状に打設することが好ましい。
固化・養生の期間は、目標とする圧縮強度が得られるまでであり、一般には7日程度以上である。
(i)浚渫場所などによって浚渫土の含水比にバラツキある場合でも、浚渫土置場に貯泥することにより、浚渫土の含水比を平均化することができる。
(ii)浚渫の工事時期に制限があり、年間で浚渫土を採取できない時期があるような場合でも、浚渫土置場に貯泥しておくことにより、浚渫土を固化体製造プロセスに安定供給することができる。
(iii)浚渫土を浚渫土置場に貯泥することにより、含水比の評価、管理及び調整を容易に行うことができる。
Claims (7)
- 泥土、結合材および粉粒状の製鋼スラグを含む混合材料の混練物を水和硬化させて得られた水和硬化体であって、単位容積当たりの質量が2000~2200kg/m3であることを特徴とする軽量人工石材。
- 28日養生後の一軸圧縮強度が15N/mm2以上であることを特徴とする請求項1に記載の軽量人工石材。
- 結合材が、高炉スラグ微粉末を80~95質量%含有し、残部が普通ポルトランドセメント、石灰粉、消石灰、高炉セメントの中から選ばれる1種以上であることを特徴とする請求項1または2に記載の軽量人工石材。
- 結合材が、高炉スラグ微粉末とフライアッシュを合計で80~95質量%含有し、残部が普通ポルトランドセメント、石灰粉、消石灰、高炉セメントの中から選ばれる1種以上であり、フライアッシュが高炉スラグ微粉末の30質量%以下であることを特徴とする請求項1または2に記載の軽量人工石材。
- 製鋼スラグが、遊離CaOを0.5質量%以上含有するスラグをエージングして粉化率2.5%以下とした製鋼スラグであることを特徴とする請求項1~4のいずれか一項に記載の軽量人工石材。
- 請求項1~5のいずれか一項に記載の軽量人工石材を製造する方法であって、含水比が180~250%である泥土、結合材および粉粒状の製鋼スラグを含み、泥土、結合材および粉粒状の製鋼スラグに対する泥土の割合が40~55容積%、製鋼スラグの配合量が混合材料体積当たり750kg/m3以上である混合材料を混練し、該混練物を水和硬化させることを特徴とする軽量人工石材の製造方法。
- 浚渫工事で発生した浚渫土であって、浚渫土置場に貯泥された浚渫土を泥土として用いることを特徴とする請求項6に記載の軽量人工石材の製造方法。
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