WO2012073258A2 - A composition suitable for use in building construction - Google Patents
A composition suitable for use in building construction Download PDFInfo
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- WO2012073258A2 WO2012073258A2 PCT/IN2011/000818 IN2011000818W WO2012073258A2 WO 2012073258 A2 WO2012073258 A2 WO 2012073258A2 IN 2011000818 W IN2011000818 W IN 2011000818W WO 2012073258 A2 WO2012073258 A2 WO 2012073258A2
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- building construction
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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
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/14—Polyepoxides
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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
- 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
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/16—Polyurethanes
-
- 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
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/18—Polyesters; Polycarbonates
-
- 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
- C04B26/22—Natural resins, e.g. rosin
-
- 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
- C04B2111/00482—Coating or impregnation materials
- C04B2111/00517—Coating or impregnation materials for masonry
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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
- 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
- C04B2111/00637—Uses not provided for elsewhere in C04B2111/00 as glue or binder for uniting building or structural materials
- C04B2111/00646—Masonry mortars
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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
- 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
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- 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
Abstract
The present invention provides a composition suitable for use in building construction which comprises water; at least one thickener; at least one pH stabilizer; at least one preservative; at least one coalescing agent; at least one binder selected from the group consisting of polyurethane, epoxy resin emulsion, rosin based emulsion, alkyd resin, vinyl acetate monomer based emulsion, vinyl ester of versatic acid, acrylic polymer, styrene polymer, CNSL emulsion, shellac emulsion, low viscosity vinyl acrylic polymer, elastomeric acrylic emulsion and silicon emulsion; bottom ash; silica particle mixture; stone grit; a filler; an extender; and optionally, at least one additive selected from the group of additives consisting of a dispersing agent, a wax emulsion and a property modifying agent.
Description
A COMPOSITION SUITABLE FOR USE IN BUILDING CONSTRUCTION
FIELD OF THE INVENTION
The present invention relates to a composition suitable for use in the building construction industry.
DEFINITION
In the context of the present invention the term "Mortar composition" includes binding mortar, adhesive mortar, plastering mortar, grouting mortar and crack filler.
BACKGROUND OF THE INVENTION
For thousands of years the architecture and construction of buildings were closely associated with the use of mortars. These 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. Inadequate curing adversely affects the hydration process and leads to cracking and shrinkage upon drying. Also, curing with hard water affects the bonding properties due to presence of contaminants. Furthermore, Portland cement based mortar suffers from some disadvantages such as delayed hardening, low tensile strength, large drying shrinkage and low chemical resistance. Also, manufacturing of Portland cement causes environmental impacts at all stages of the process due to substantial emission of carbon dioxide which results in global warming.
Generally, 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. However, 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.
EXISTING KNOWLEDGE
Following patent applications/granted patents disclose various binding compositions employed as building materials.
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. However, the 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. Also, 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.
Our PCT application WO09007994, hereafter please refer to as PCT application, 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. However, the required bond strength of the mortar has not been achieved when low-viscosity vinyl acetate and fly ash were employed in the composition.
GB2438072 discloses 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.
The 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.
Thus, there is felt a need to develop a composition suitable for use in building construction which is completely Portland cement free and in ready to use form. Also, to develop a product
which does not require any pre-wetting or post-curing with water which saves time, manual labour and precious water and at the same time has the desired bond strength.
OBJECTIVES OF THE INVENTION
It is an object of the present invention to provide a Portland cement free construction material composition having improved properties such as adhesion, thickening and application behavior and compressive strength.
Another object of the present invention is to provide a construction material 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 material 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 material composition with extended pot life and shelf life.
Yet another object of the present invention is to provide a construction material composition which is non hazardous for the applicator and the end user.
Yet another object of the present invention is to provide a construction material composition which saves time in application, manual labour.
Still another object of the present invention is to provide a construction material composition which uses the major pollutants and hence offers an environmental friendly composition.
Still another object of the present invention is to provide a construction material composition which is hassle free.
Still another object of the present invention is. to provide a construction material composition which can be directly applied on brick walls, concrete blocks, fly ash bricks, concrete materials, stone, ply boards and asbestos sheets.
Still further object of the present invention is to provide a construction material composition which is integrally cost-effective.
Still further object of the present invention is to provide a construction material composition which is based on air drying/curing.
One more object of the present invention is to provide a construction material composition which has adequate bond strength, offers good weather resistance and better resistance to water wetting.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a composition suitable for use in building construction comprising:
a. water selected from the group consisting of demineralized water obtained by reverse osmosis, distilled water, deionized water, soft water and demineralized water free from bacteria, in an amount of about 4% to about 49% of the mass of the total composition;
b. at least one thickener selected from the group consisting of acrylic polymer, acrylic emulsion copolymer, hydroxyethylcellulose, acrylic copolymer and crystalline hydrated magnesium aluminium silicate, in an amount of about 0.15% to about 4% of the mass of the total composition;
c. at least one pH stabilizer selected from the group consisting of liquid ammonia, triethylamine, ammonium chloride, in an amount of about 0.45% to about 1.5% of the mass of the total composition;
d. at least one preservative selected from the group consisting of chloromethyl- methylisothiazolone formaldehyde, carbendazim-octylisothiazolone and isothiazo-linones, in an amount of about 0.05% to about 1.25% of the mass of the total composition;
e. at least one coalescing agent selected from the group consisting of monoethylene glycol, diethylene glycol, propylene glycol, Texanol, mixed xylene, and hexane, in an amount of about 0.22% to about 2.25% of the mass of the total composition; f. at least one binder having intrinsic viscosity in the range of 250 cps to 4000 cps, selected from the group consisting of polyurethane, epoxy resin emulsion, rosin
based emulsion, alkyd resin, vinyl acetate monomer based emulsion, vinyl ester of versatic acid, acrylic polymer, styrene polymer, CNSL emulsion, shellac emulsion, low viscosity vinyl acrylic polymer, elastomeric acrylic emulsion and silicon emulsion, in an amount of about 2% to about 45% of the mass of the total composition;
g. bottom ash with a 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 with 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;
i. stone grit of hardness greater than 2 on the Mohs scale in an amount of about 0% to about 50 % of the mass of the total composition;
j. a filler in an amount of about 0% to about 55% of the mass of the total composition;
k. an extender selected from the group of extenders consisting of china clay, chalk, talc, barytes, quartz powder and dolomite in an amount of about 0% to about 75% of the mass of the total composition; and
1. optionally, at least one additive selected from the group of additives consisting of a dispersing agent, a wax emulsion and a property modifying agent.
Typically, the property modifying agent is selected from the group consisting of flue ash, calcium hydroxide, sodium silicate, sodium hydroxide, potassium dichromate, slag, recycled silica from casting industry, crushed sand and gypsum-.
Typically, the proportion of the property modifying agent is 0.1 % to 10% of the mass of the total composition.
Typically, the pH stabilizer is liquid ammonia having concentration in the range of 0.5 to 2.0%.
Typically, the binder is anionic pre-polymerized binder containing homopolymer.
In accordance with another embodiment of the present invention the binder is anionic pre- polymerized binder comprising acrylic and styrene copolymer in a ratio of 70:30 to 50:50.
Typically, the glass transition temperature of the binder is in the range of about 10 C to 50 C.
In accordance with another embodiment of the present invention said composition further comprises fly ash in an amount of 0% to 76% of the mass of the total composition.
Typically, the silica is at least one selected from the group consisting of crystalline silica derived from rice husk, sugar cane trash, biomass material, foundry silica, quarry silica, river bed silica and seashore silica.
In one of the embodiment the slag includes but is not limited to slag sourced from steel and other metal furnaces.
Typically, the silica particle mixture comprises 10% of silica particles of size 1.7 mm, 30% of silica particles of size 1.4 mm, 14% of silica particles of size 0.4 mm and 55% of silica particles of size 0.2 mm.
In accordance with another embodiment of the present invention the silica particle mixture comprises 93.33% of silica particles of size 0.4mm and 6.67% of silica particles of size 0.2 mm.
In accordance with still another embodiment of the present invention the silica particle mixture comprises 10% of silica particles of size 0.2 mm and 90% of silica particles of size 0.6 mm.
Typically, the stone grit has irregular shapes and has a particle size in the range of 1mm to 4mm.
Typically, the stone grit is selected from the group consisting of shahabad stone grit, kotta stone grit, basalt stone grit, granite stone grit, sandstone stone grit, limestone stone grit, marble stone grit, soapstone stone grit and slate stone grit.
Typically, the filler is at least one selected from the group 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, powdered vermiculite and perlite.
In accordance with another embodiment of the present invention the composition includes wax emulsion in an amount of 0.1% to 5% of the mass of the total composition.
DETAILED DESCRIPTION OF THE INVENTION
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.
The 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.
The inventors of the present invention further tried different types of binders in order to replace acrylic emulsion binder fully or partially in the formulations. Still further, inventors also tried to improve the properties of the formulation such as adhesion, thickening and application behavior, rate of initial and final setting & compressive strength.
Thus, in accordance with the present invention there is provided 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; at least one thickener in an amount of about 0.15%) to about 4% of the mass of the total composition; at least one pH stabilizer in an amount of about 0.45% to about 1.5% of the mass of the total composition; at least one preservative in an amount of about 0.05% to about 1.25% of the mass of the total composition; at least one coalescing agent in an amount
of about 0.22% to about 2.25% of the mass of the total composition; at least one 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; 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; silica particle mixture with 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; stone grit of hardness of above 2 on the Mohs scale and having particle size of about 0.5 mm to 4 mm in an amount of about 0 % to about 50 % 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, an extender in an amount of 0% to 75% of the mass of the total composition and optionally, at least one additive selected from the group of additives consisting of a dispersing agent, a wax emulsion and a property modifying agent.
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 consistency for use to which the composition is to be applied.
In order to control the flow and viscosity of said composition, 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. Preferably, in accordance with the present invention, 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. In accordance with one preferred embodiment of the present invention, the pH stabilizer is liquid ammonia having concentration in the range of 15 to 20%. Alternatively, the pH stabilizer is triethylamine.
In order to increase the shelf life of the composition it is desirable to include a preservative in said composition. 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, Texanol, mixed xylene, and hexane. In accordance with one embodiment of the present invention, the coalescing agent used is mixed xylene. In accordance with the present invention, the coalescing agent is diethylene glycol.
The binder is at least one selected from the group consisting of acrylic polymer, styrene polymer, CNSL (cashew nut shell liquid) emulsion, shellac emulsion, low viscosity vinyl acrylic polymer, elastomeric acrylic emulsion, silicon emulsion, water based polyurethane dispersion, epoxy resin based emulsion, Rosin based emulsion, alkyd resins based emulsion, vinyl acetate monomer based emulsion (VAM), ethylene vinyl actetate emulsion and vinyl ester of versatic acid (VAM- VEOVA) based emulsion. 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.
In accordance with another embodiment of the present invention, the binder is water dispersible anionic pre-polymerized binder containing homopolymer or a copolymer.
The composition prepared with the water based Polyurethane dispersions as a binder gives better strength to the final product. It also aids the fast rate setting, better resistance to water wetting and softening of the final product. However, it provides very poor consistency to the products. When the water based Polyurethane dispersions as a binder are partially or fully replaced with acrylic based emulsions the properties including strength, hardness and curing rate of the final product made in accordance with the present invention are considerably improved.
Preferably, the Polyurethane dispersion based binder in said composition is present in an amount of about 10% to about 45% of the total mass of the composition.
The epoxy bis-phenol glycedyl resins of suitable molecular weight (4000-6000) are converted to esters by reacting with oxidizing vegetable oil fatty acids and further emulsified. These Emulsified epoxy resins when used as a binder in said composition offer good applicability in addition to the earlier resistance properties to the final product made in accordance with the present invention.
The composition made with anionic pre-polymerized acrylic polymer as a binder gives excellent outdoor durability and excellent adhesion under damp or dry conditions.
In accordance with other embodiment of the present invention, the binder is anionic pre- polymerized binder which 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. Alternatively, 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 -22°C to 1 .10°C. The pH of the anionic prepolymerized binder is in the range of 3 to 10. In accordance with the present invention 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. More preferably, the anionic pre-polymerized binder contains particulate monomeric units in the form of suspended monomeric particles having particle size in the range of about 0.01 to 4 microns.
In accordance with one of the embodiments of the present invention, the bottom ash is ash obtained from a wet bottom coal combustion boiler or from a dry bottom coal combustion boiler in a thermal power plant. The bottom ash used in the present invention has loss of ignition less than about 0.5 %.The bottom ash when used with other inert inorganic materials gives bulk to the product.
Alternatively, said composition includes fly ash in an amount of 0% to 76 % 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.
In accordance with the present invention, said composition contains crystalline silica which is derived from rice husk. In another embodiment the silica is selected from the group consisting of fumed silica, silica from sugar cane trash, silica from biomass material and the like. Other
sources are river bed silica, quarry silica, foundry silica and seashore silica. In accordance with one embodiment of the present invention, said composition comprises a silica particle mixture having particle size less than 2 mm. In accordance with other embodiment of the present invention, 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. In accordance with another embodiment of the present invention, 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. In accordance with yet another embodiment of the present invention, 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%.
In accordance with the present invention, said composition contains stone grit having particle size in the range of 1 mm to 4mm with irregular shapes. The stone is at least one selected from the group of stones consisting of shahabad, kotta, basalt, granite, sandstone, limestone, marble, soapstone and slate.
In accordance with the present invention, said composition also contains a filler which is at least one selected from the 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, powdered vermiculite and perlite. In accordance with the present invention, the filler is in an amount of about 0% to about 55% of the mass of the total composition.
It has been found that, mixing of bottom ash with lightweight inert inorganic material like fillers, silica and stone grit having different particle sizes is beneficial as it supports the faster drying of the product, improves the water resistance due to close packing of particles and mechanical strength and shear strength of the product.
In accordance with the present invention, the composition contains an extender and is at least one extender selected from the group of extenders consisting of china clay, super chalk, talc, barites,
quartz powder and dolomite. In accordance with the present invention the extender is in an amount of about 0% to about 75% of the mass of the total composition.
When the aforementioned composition is mixed with modifying agents, the properties including strength, adhesion, hardness and curing rate of the final product made in accordance with the present invention are considerably improved.
The property modifying agent is at least one selected from the group consisting of flue ash (very fine fly ash with fineness upto 500 m2/kg), sodium silicate (water glass), sodium hydroxide , calcium hydroxide, gypsum (calcium sulfate), potassium dichromate, slag, recycled silica from casting industry, crushed sand and is present in an amount of about 0.1 to about 10% of the mass of the total composition.
In one of the embodiment the slag includes but is not limited to slag sourced from steel and other metal furnaces.
The composition provided in accordance with the present invention when mixed with flue ash with fineness upto 500m2 kg and 5% residue on 45 micron sieve along with the bottom ash, the strength and hardness of the final product are considerably enhanced.
In accordance with the present invention, said composition optionally contains wax emulsion in an amount of about 0.1 % to about 5% of the mass of the total composition.
The 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.'
The composition suitable for use in building construction disclosed in accordance with the present invention is free from Portland cement.
In accordance with another aspect of the present invention there is provided a process for manufacturing of composition suitable for use in building construction. The process involves the following steps:
In the first step, water, at least one thickener selected from the group consisting of acrylic polymer, acrylic emulsion copolymer, hydroxyethylcellulose, acrylic copolymer and crystalline
hydrated magnesium aluminium silicate, in an amount of about 0.15% to about 4% of the mass of the total composition, at least one pH stabilizer selected from the group consisting of liquid ammonia, triethylamine, ammonium chloride and ammonium hydroxide, in an amount of about 0.45% to about 1.5% of the mass of the total composition, at least one preservative selected from the group consisting of chloromethyl-methylisothiazolone formaldehyde, carbendazim- octylisothiazolone and isothiazolinones, in an amount of about 0.05% to about 1 .25% of the mass of the total composition, at least one coalescing agent selected from the group consisting of monoethylene glycol, diethylene glycol, propylene glycol, texanol, mixed xylene, and hexane, in an amount of about 0.22% to about 2.25% of the mass of the total composition and at least one binder selected from the group consisting of polyurethane, epoxy resin emulsion, rosin based emulsion, alkyd resin, vinyl acetate monomer based emulsion, vinyl ester of versatic acid, acrylic polymer, styrene polymer, CNSL emulsion, shellac emulsion, low viscosity vinyl acrylic polymer, elastomeric acrylic emulsion and silicon emulsion, in an amount of about 2% to about 45% of the mass of the total composition are mixed in a disperser/mixer to obtain a first concentrate. Typically, the mixing is carried out at a speed of about 1000- 1500 rpm for 2 to 3 hours. Preferably, this step is carried out at a speed of about 1400-1500 rpm.
In the second step, an appropriate amount of water, bottom ash, silica, stone grit and optionally at least one additive selected from the group consisting of a dispersing agent, a wax emulsion and a property modifying agent are added to the first concentrate, at a speed of about 700 to 800 rpm to obtain a mixture.
Typically, the property modifying agent is selected from the group consisting of flue ash, calcium hydroxide, sodium silicate, sodium hydroxide, potassium dichromate, slag, recycled silica from casting industry, crushed sand and gypsum.
Finally, the obtained mixture is homogenized at a speed of about 400-800 rpm to obtain a composition suitable for use in building construction. Preferably, this step is carried out at a speed of about 600-700 rpm.
In accordance with one of the embodiments of the present invention the thickener and the pH stabilizer are added simultaneously.
In accordance with the present invention the mixing and/ or homogenizing is carried out in a mixer selected from the group consisting of a pan mixer, a concrete mixer, a stainless steel high speed mixer, a stainless steel pug mixer and combinations thereof.
In accordance with one embodiment of the present invention all the ingredients of the composition are charged to a pan mixer or a concrete mixer in any sequence for mixing. Typically, the mixing in a pan mixer or a concrete mixer is carried out at a speed of about 10 to 600 rpm. Preferably, the mixing is carried out at a sped of about 300rpm.
In accordance with another embodiment of the present invention the mixing is carried out in a mixer selected from the group consisting of a stainless steel high speed mixer, a stainless steel pug mixer and combinations thereof.
Typically, the stainless steel high speed mixer is operated at 1000 to 1500 rpm. Typically, the stainless steel pug mixer is operated at a speed of about 400 to 800 rpm.
EXAMPLES
The invention will now be described with respect to the following examples which do not limit the invention in any way and only exemplify the invention.
Example 1
(12 ml) of water, (0.3gm) of acrylic polymer, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate, (15 %) of polyurethane dispersion (PUD) and (0.15%) of organic gellant as (polyurethane dispersion thickener) were mixed at room temperature in a stainless steel high speed mixer at a speed of 1400 rpm to obtain a first concentrate. To this, (4.7ml) of water, (46.7gm) of bottom ash having particle size of 60 microns, (22 gm) of silica particle mixture having particle size of 400 to 1000 microns and 7.16 gm of shahabad stone grit with hardness of >2 Mho were incorporated. The whole mixture was then mixed at a speed of about 600 rpm to obtain a homogeneous mixture suitable for use in building construction having density 1.4 kg/ltr.
The composition was then tested for compressive strength, adhesion test, thickening behavior, application behavior, and rate of initial and final setting.
It was observed that, due to the presence of poly urethane dispersion as a binder, the strength of the final product was improved. Also, the drying time of the material was lesser which facilitates the setting of the final product at faster rate. The material upon drying showed better resistance to water wetting and softening. Product has poor consistency.
Example 2
( 12ml) of water, (0.3gm) of acrylic polymer, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate and (20%) of epoxy emulsion were mixed at room temperature in a stainless steel pug mixer at a speed of 700 rpm to obtain a first concentrate. To this, (4.7ml) of water, (46.7gm) of bottom ash having particle size of 60 microns, (20 gm) of silica particle mixture having particle size of 400 to 1000 microns and 7.16 gm of shahabad stone grit with hardness of >2 Mho were incorporated. The whole mixture was then mixed at a speed of about 600 rpm to obtain a homogeneous mixture suitable for use in building construction having density 1.48. Cobalt lead drier was used in 0.1 to 0.3 gm.
The composition was then tested for compressive strength, adhesion test, thickening behavior, application behavior, and rate of initial and final setting.
The composition as illustrated in Example 2 containing epoxy resin as a binder showed good applicability of the final product along with the improved water resistance properties.
Example 3
(20ml) of water, (0.3gm) of acrylic polymer, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate and (20 %) of Modified Rosin were mixed at room temperature in a pan mixer at a speed of 500 rpm to obtain a first concentrate. To this, (43.7gm) of bottom ash having particle size of 60 microns, (22 gm) of silica particle mixture having particle size of 400 to 1000 microns and 7.16 gm of shahabad stone grit with hardness of >2 Mho were incorporated were incorporated. The whole mixture was then mixed at a speed of about 300 rpm to obtain a homogeneous mixture suitable for use in building construction having density 1 .5.
The composition was then tested for compressive strength, adhesion test, thickening behavior, application behavior, and rate of initial and final setting.
Faster setting rate of the final product was observed due to the presence of ester modified Rosins as a binder in said composition prepared in accordance with the present invention but strength was lesser than PUD and epoxy based compositions.
Example 4
( 18ml) of water, (0.3gm) of acrylic polymer, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate and ( 15%) of alkyd resin emulsion (50%solids) were mixed at room temperature in a concrete mixer at a speed of 450 rpm to obtain a first concentrate. To this, (46.7gm) of bottom ash having particle size of 60 microns, (22 gm) of silica particle mixture having particle size of 400 to 1000 microns and 7.16 gm of shahabad stone grit with hardness of >2 Mho were incorporated were incorporated. The whole mixture was then mixed at a speed of about 300 rpm to obtain a homogeneous mixture suitable for use in building construction having density 1.45.
The composition was then tested for compressive strength, adhesion test, thickening behavior, application behavior, and rate of initial and final setting.
Poof results in terms of extended drying time were observed when the composition is prepared by using alkyd resin as the Binder.
Example 5
( 10 ml) of water, (0.3gm) of acrylic polymer as thickener, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate and ( 15%) of VAM emulsion were mixed at room temperature in a stainless steel high speed mixer at a speed of 1300 rpm to obtain a first concentrate. The first concentrate was then transferred to a pug mixer .To this, (4.7ml) of water, (46.7gm) of bottom ash having particle size of 60 microns, (24gm) of silica particle mixture having particle size of 400 to 1000 microns and 7.16 gm of shahabad stone grit with hardness of >2 Mho were incorporated were incorporated. The whole mixture was then mixed at a speed of about 500 rpm to obtain a homogeneous mixture suitable for use in building construction having density 1.4kg/ltr.
The composition was then tested for compressive strength, adhesion test, thickening behavior, application behavior, and rate of initial and final setting.
Better results were observed in faster setting due to the presence of vinyl acetate monomer (VAM) emulsions, however the setting time was slow and compressive strength was lesser as compared to the composition made with the other binders.
Example 6
(15 ml) of water, (0.3gm) of acrylic polymer, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate and (15%) VAM - VEOVA of were mixed at room temperature in a stainless steel high speed mixer at a speed of 1200 rpm to obtain a first concentrate. The obtained first concentrate was then transferred to a concrete mixer. To this, (4.7ml) of water, (46.7gm) of bottom ash having particle size of 60 microns, (20 gm) of silica particle mixture having particle size of 400 to 1000 microns and 7.16 gm of shahabad stone grit with hardness of >2 Mho were incorporated were incorporated. The whole mixture was then mixed at a speed of about 400 rpm to obtain a homogeneous mixture suitable for use in building construction having density 1.55kg/ltr.
The composition was then tested for compressive strength, adhesion test, thickening behavior, application behavior, and rate of initial and final setting.
The composition made with VAM- VEOVA was found to be cost-effective compared to the other compositions. Better results in terms of improved drying time were observed due to the presence of VAM-VEOVA emulsions; however the strength was lesser as compared to the composition made with the other binders.
Example 7
( 10 ml) of water, (0.3gm) of acrylic polymer, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate and (6 %) of acrylic emulsion were mixed at room temperature in a stainless steel pug mixer at a speed of 800 rpm to obtain a first concentrate. The obtained first concentrate was transferred to a pan mixer. To this, (4.7ml) of water, (46.7gm) of bottom ash having particle size of 60 microns, (24 gm) of silica particle mixture having particle size of 400 to 1000 microns, (5 gm) of sodium silicate in presence of 2.5 gm sodium hydroxide and 7.16 gm of shahabad stone grit with hardness of >2 Mho were incorporated were incorporated. The whole mixture was then mixed at a speed of about 300 rpm to obtain a homogeneous mixture suitable for use in building construction having density 1.5 gm/ltr.
The composition was then tested for compressive strength, adhesion test, thickening behavior, application behavior, and rate of initial and final setting.
It has been observed that upon drying, the composition, prepared in accordance with the abovementioned example showed at least 25% improved hardness with faster setting time (faster by at least 10 %) over the prior trials carried out without using property modifying agents.
Example 8
( 16 ml) of water, (0.3gm) of acrylic polymer, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate and (7%) of acrylic emulsion were mixed at room temperature in a stainless steel high speed mixer at a speed of 1 100 rpm to obtain a first concentrate. The obtained first concentrate was transferred to a pug mixer. To this, (4.7ml) of water, (30 gm) of bottom ash having particle size of 60 microns, ( 18 gm) of silica particle mixture having particle size of 400 to 1000 microns, 7.16 gm of shahabad stone grit with hardness of >2 Mho, (8 gm) of Calcium hydroxide were incorporated. The whole mixture was then mixed at a speed of about 700 rpm to obtain a homogeneous mixture suitable for use in building construction having density 1.5 kg/ltr.
It was observed that, the final product prepared in accordance with the abovementioned composition becomes lighter in appearance and showed better and faster hardening and drying after application. However, best strength was found to be obtained after 90 days after application of said composition.
Example 9
(20 ml) of water, (0.3gm) of acrylic polymer, (0.12ml) of liquid ammonia having concentration of 15%, (0.5gm) of chloromethyl-methylisothiazolone, (0.59ml) of gentamicin sulphate and (7%) of Acrylic emulsion were mixed at room temperature in a stainless steel high speed mixture at a speed of 1400 rpm to obtain a first concentrate. The first concentrate was then transferred to a pan mixer. To this, (46.7gm) of bottom ash having particle size of 60 microns, (22 gm) of silica particle mixture having particle size of 400 to 1000 microns, 16gm of shahabad stone grit with hardness of >2 Mho and (0.1 gm) of Potassium dichromate were incorporated. The whole mixture was then mixed at a speed of about 450 rpm to obtain a homogeneous mixture suitable for use in building construction having density.
The applied samples were exposed to sunlight, to ensure reaction in the presence of UV rays with dichromates which usually show good hardening of acrylic and styrene polymers in combination with Potassium dichromate. No significant change was observed in the final application in terms of drying, hardness. However, the composition prepared in accordance with the Example-9 was not found to be useful due to the thickness of the final product.
Trials :
The inventors of the present invention carried out several experimental trials using different binders and property modifying agents.
A] Binder Trials:
The formulations for the present invention have been finalized considering various aspects and parameters during application and post application. Trials have also been carried out in order to replace acrylic emulsion binder fully or partially in the formulations. The main properties being concentrated on are: adhesion, thickening and application behavior, rate of initial and final setting & compressive strength.
1. Polyurethane dispersions (PUD) as available in the market have been tried as binder in the basic formulation replacing the acrylic and polystyrene emulsion and found to be useful in the strength of final products. PUD offers fast rate of setting, better resistance to water wetting and softening. Mixing operation is easier; settling of solids in the final composition is more. Considering the prevalent solid content of PUD (generally 30-35% and 32% in present case) the quantity used varies between 10 to 45% of the formulations. The thickening effect is provided by fine fillers like fly ash. Thickeners like inorganic gallants have been used.
2. Epoxy emulsions - Epoxy, bis- phenol glycedyl resins of suitable molecular weight (40000- 60000) are converted to esters by reacting with oxidizing vegetable oil fatty acids and further emulsified has been tried to offer good applicability in addition to earlier resistance properties. The curing of the final products is affected with the help of metallic driers like cobalt and lead.
3. Modified Rosin (Colophony): Rosin has been found to work in certain formulations to a limited extent as a binder because it has fast setting properties but stickiness problem in the final composition. Therefore, rosin has been modified to esters like maleic, limed, Zinc, glycerin and penta-erythritol.
4. Alkyd resins: Vegetable oil fatty acid modified alkyd resins based on phthalic anhydrate and glycerol /penta ester and further modified as emulsion offer good dispersion to fly ash of both origins viz. flue as well as bottom. The foaming was also found to reduce in case of alkyd resins.
5. Similar experiments using Linseed stand oil of elevated viscosity range has also been tried out as binders. The stand oils are preheated polymerized linseed oil. The compositions made with this binder shows slow setting in final application.
6. VAM- Vinyl Acetate Monomer - was tried to replace acrylic emulsion binder fully or partially in the formulations .The results were satisfactory , while setting time was slow and compressive strength is lesser compared to other formulations.
7. VAM VEOVA modified acrylic emulsions (10 to 100% replacement) emulsion - trials carried out using VAM VEOVA emulsion showed reasonable results. This composition is cost effective compared to the other compositions.
B] Property modifiers trials:
Trials have been carried out to study the effect of property modifying agents with respect to life span of formulation and post setting hardening.
1. Flue ash: Fly ash is found to have varying silica reactivity and fineness in particle size. This leads to larger surface area per gram weight. The flue ash has been found to offer better strength with time when used in combination with pond ash/ bottom ash. The composition of flue and bottom ash used has been found to be satisfactory in all proportions from 0-100%.
2. Sodium silicate (water glass) with 20% silicate has been found to affect setting of acrylic and polystyrene emulsions. The formation of sodium silicate hydrate plays important role in hardness of the product upon drying.
3. Calcium hydroxide- Effect of calcium hydroxide (as lime) has been studied in combination with fly ash and bottom ash at different proportions. As per lime reactivity of ash, different compositions have been tried and studied. Lime to ash ratio tried are 10 to 40%., lime reactivity with the fly ash or bottom ash results in the formation of calcium silicate hydrate commonly known as CSH, which is formed by the reaction of active silica from bottom ash and fly ash and water.
4. Gypsum- it has been observed that the useable life is reduced due to water reactivity of gypsum. It appears suitable to add the gypsum as a separate component prior to using, instead of mixing it in a single component product.
5. Potassium dichromate - has been tried as a catalyst for fast setting of emulsions on exposure to sun rays.
6. Sodium hydroxide - sodium hydroxide was used in the formulation in the form of 40 % solution in water. Effect was studied at 5 to 15 % concentrations in the formulation. The resultant formulation had excellent toughness, however the pH was found to be highly alkaline
7. Slag from steel mills, recycled silica from casting industry, crushed sand as recycled product from aggregate quarries, mined silica-These materials were tried in the concentrations ranging from 5 to 70 %. The materials showed significant improvements in mechanical strength of the resultant formulation.
8. In some composition complete replacement of fillers with slag have been tried. It is observed that the flow may not be satisfactory for operations in some applications.
The compositions of various trials are provided in the following tables.
Table No. 1
Table No. 2
Table No. 3
TECHNICAL ADVANCEMENT
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.
The composition of the present invention posses various improved properties such as adhesion, thickening and application behavior, compressive strength, extended life, toughness and mechanical strength.
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 release of carbon dioxide 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. The 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.
ECONOMIC SIGNIFICANCE:
Conventional composition employed in the building construction is mainly based on Portland cement, sand and water in which all the ingredients are mixed on-site. On the other hand, 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.
In conventional cementitious mortars, raw material handling, mixing and curing involves more transportation cost, labour and time and thus increases the overall capital investment.
Furthermore, conventional cementitious mortar needs a separate inventory for sand, cement and water; however, the composition prepared in accordance with present invention is a one time inventory thus further saving ample amount of time, transportation and capital. Hence, the overall cost of the masonry work involved in the building construction is reduced by 2-3%.
The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention and the claims unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific ingredients of the preferred composition, it will be appreciated that many additional ingredients can be added and that many changes can be made in the preferred composition without departing from the principles of the invention. These and other changes in the preferred composition of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.
Claims
1. A composition suitable for use in building construction comprising:
a. water selected from the group consisting of demineralized water obtained by reverse osmosis, distilled water, de-ionized water, soft water and demineralized water free from bacteria, in an amount of about 4% to about 49% of the mass of the total composition;
b. at least one thickener selected from the group consisting of acrylic polymer, acrylic emulsion copolymer, hydroxyethylcellulose, acrylic copolymer and crystalline hydrated magnesium aluminium silicate, in an amount of about 0.15% to about 4% of the mass of the total composition;
c. at least one pH stabilizer selected from the group consisting of liquid ammonia, triethylamine, ammonium chloride and ammonium hydroxide, in an amount of about 0.45% to about 1.5% of the mass of the total composition;
d. at least one preservative selected from the group consisting of chloromethyl- methylisothiazolone formaldehyde, isothiazolinones and carbendazim-octyliso- thiazolone, in an amount of about 0.05% to about 1.25% of the mass of the total composition;
e. at least one coalescing agent selected from the group consisting of monoethylene glycol, diethylene glycol, propylene glycol, taxonol, mixed xylene, gentamicin sulphate and hexane, in an amount of about 0.22% to about 2.25% of the mass of the total composition;
f. at least one binder having intrinsic viscosity in the range of 250 cps to 4000 cps, selected from the group consisting of polyurethane, epoxy resin emulsion, rosin based emulsion, alkyd resin, vinyl acetate monomer based emulsion, vinyl ester of versatic acid, acrylic polymer, styrene polymer, CNSL emulsion, shellac emulsion, low viscosity vinyl acrylic polymer, elastomeric acrylic emulsion and silicon emulsion, in an amount of about 2% to about 45% of the mass of the total composition;
g. bottom ash with a 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 with 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;
i. stone grit of hardness of greater than 2 on the Mohs scale in an amount of about 0 % to about 50 % of the mass of the total composition;
j. a filler in an amount of about 0 % to about 55 % of the mass of the total composition;
k. an extender selected from the group of extenders consisting of china clay, chalk, talc, barites, quartz powder and dolomite in an amount of about 0 % to about 75 % of the mass of the total composition; and
1. optionally, at least one additive selected from the group of additives consisting of a dispersing agent, a wax emulsion and a property modifying agent.
2. A composition suitable for use in building construction as claimed in claim 1 , wherein the property modifying agent is selected from the group consisting of flue ash, calcium hydroxide, sodium silicate, sodium hydroxide, potassium dichromate, slag, recycled silica from casting industry, crushed sand and gypsum.
3. A composition suitable for use in building construction as claimed in claim 1 , wherein the proportion of the property modifying agent is 0. 1% to 10% of the mass of the total composition.
4. A composition suitable for use in building construction as claimed in claim 1 , wherein the pH stabilizer is liquid ammonia having concentration in the range of 15% to 30%.
5. A composition suitable for use in building construction as claimed in claim 1 , wherein the binder is anionic pre-polymerized binder containing homopolymer.
6. A composition suitable for use in building construction as claimed in claim 1 , wherein the binder is anionic pre-polymerized binder comprising acrylic and styrene copolymer in a ratio of 70:30 to 50:50.
7. A composition suitable for use in building construction as claimed in claim 1 , wherein the glass transition temperature of the binder is in the range of about 10°C to 50°C.
8. A composition suitable for use in building construction as claimed in claim 1 , wherein said composition further comprises fly ash in an amount of 0% to 76% of the mass of the total composition.
9. A composition suitable for use in building construction as claimed in claim 1 , wherein the silica is at least one selected from the group consisting of crystalline silica derived from rice husk, sugar cane trash, biomass material, foundry silica, quarry silica, river bed silica and seashore silica.
10. A composition suitable for use in building construction as claimed in claim 1 , wherein the silica particle mixture comprises 10% of silica particles of size 1.7 mm, 30% of silica particles of size 1.4 mm, 14% of silica particles of size 0.4 mm and 55% of silica particles of size 0.2 mm.
1 1. A composition suitable for use in building construction as claimed in claim 1 , wherein the silica particle mixture comprises 93.33% of silica particles of size 0.4mm and 6.67% of silica particles of size 0.2 mm.
12. A composition suitable for use in building construction as claimed in claim 1 , wherein the silica particle mixture comprises 10% of silica particles of size 0.2 mm and 90% of silica particles of size 0.6 mm.
13. A composition suitable for use in building construction as claimed in claim 1 , wherein the stone grit has irregular shapes and has a particle size in the range of 1 mm to 4mm.
14. A composition suitable for use in building construction as claimed in claim 1 , wherein the stone grit is selected from the group consisting of shahabad stone grit, kota stone grit, basalt stone grit, granite stone grit, sandstone stone grit, limestone stone grit, marble stone grit, soapstone stone grit and slate stone grit.
15. A composition suitable for use in building construction as claimed in claim 1 , wherein the filler is at least one selected from the group 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, titanium oxide, calcium carbonate, iron oxide, mica, powdered vermiculite and perlite.
16. A composition suitable for use in building construction as claimed in claim 1 , wherein the composition includes wax emulsion in an amount of 0.1 % to 5% of the mass of the total composition.
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| US10954162B1 (en) | 2019-09-24 | 2021-03-23 | Geopolymer Solutions, LLC | Protective coating |
| CN113372034A (en) * | 2021-07-06 | 2021-09-10 | 河南三棵树新材料科技有限公司 | Aggregate for preparing cement-based ceramic binder and preparation method thereof |
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| GB2619366A (en) * | 2022-05-31 | 2023-12-06 | Newall Plant Ltd | Building Materials and Method of Production thereof |
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| CN112375487A (en) * | 2020-11-23 | 2021-02-19 | 安徽嘉年华漆业有限公司 | Water-based paint for waterproof exterior wall of building and spraying method thereof |
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| CN113620618A (en) * | 2021-08-24 | 2021-11-09 | 武汉理工大学 | Method for preparing integrated cementing material by utilizing granite powder and coal slag |
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| CN115386247A (en) * | 2022-08-26 | 2022-11-25 | 马鞍山顾地塑胶有限公司 | In-situ surface coating modified calcium carbonate filler and preparation method and application thereof |
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