WO2013063743A1 - Mortier haute performance pour système de finition d'isolation extérieure - Google Patents
Mortier haute performance pour système de finition d'isolation extérieure Download PDFInfo
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- WO2013063743A1 WO2013063743A1 PCT/CN2011/081560 CN2011081560W WO2013063743A1 WO 2013063743 A1 WO2013063743 A1 WO 2013063743A1 CN 2011081560 W CN2011081560 W CN 2011081560W WO 2013063743 A1 WO2013063743 A1 WO 2013063743A1
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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
- C04B28/04—Portland cements
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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
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/2038—Resistance against physical degradation
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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
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/29—Frost-thaw resistance
Definitions
- the present invention relates to a mortar composition used in construction industry. Particularly, the present invention relates to a polymer mortar composition applicable for EIFS construction withstanding weathering test including wet freeze-thaw circulation.
- Exterior Insulation Finish System is an exterior wall cladding system, and is also known as External Thermal Insulation Systems (ETICS) in Europe. It can be used on both residential and commercial buildings for the purpose of saving energy, improving room comfort and protecting walls against moisture and other external elements.
- EIFS normally comprises a thermal insulation layer and polymer mortar layers.
- Polymer mortar layers are normally used as an adhesive layer for adhering a thermal insulation board onto a substrate, such as an outer wall, and as a basecoat layer for leveling the surface to which a finish layer would be applied and reinforcing the flexibility of the system.
- EIFS should have certain flexibility to maintain integrity even with slight deformity and outer impact. Impact resistance is a critical factor for evaluating flexibility of EIFS, especially for the building structures having a lower altitude, which are vulnerable to impact by accident.
- Discovery of the present invention is partly a result of discovering a problem with current EIFS structures. It has been discovered that when EIFS are submersed in water during a weathering test water likely penetrates through the polymer mortar of the EIFS, resulting in a reduction in impact resistance of the EIFS. Water that penetrates the polymer mortar can accelerate a second hydration of the mortar, which increases stiffness of the mortar in the EIFS, resulting in a loss in flexibility.
- the polymer of a polymer mortar forms a film between inorganic particles, such as fillers, inside the polymer mortar. When the polymer gets wet, bonding strength of the polymer reduces thereby weakening the mortar. More seriously, when immersed water is frozen within a mortar, the mortar structure tends to be destroyed due to volume expansion of frozen water.
- the present invention provides a mortar composition
- a mortar composition comprising 20 percent (%)- 35% by weight of Portland cement, 55%-70% by weight of fillers, 0.05%-0.5% by weight of cellulose ether, 6%-8.5% by weight of redispersible polymer powder and/or polymer emulsion, 0.05%-0.5% by weight of a hydrophobic agent, 0.05%-0.5% by weight of polymer fibers, and 0.2%- 1.5% by weight of early strength agent, with percentages based on total dry weight of said mortar composition.
- the inventive mortar composition comprises 23%-27% by weight of
- a mortar layer prepared from the inventive mortar composition meet the EIFS requirements including the impact resistance and the ratio of compressive strength to flexural strength under China Industrial Code JG149-2003.
- Re-dispersible power is typically made by spray drying emulsion polymer in the presence of various additives such as a protective colloid, anti-caking agent, etc.
- various additives such as a protective colloid, anti-caking agent, etc.
- Many types of polymers can be used to produce RDP including vinyl ester-ethylene copolymers, such as ethylene/vinylacetate copolymer, vinylacetate/vinyl-versatate copolymer,
- styrene/acrylic esters copolymers etc.
- the dispersion of the copolymer if appropriate together with protective colloids, is sprayed and dried.
- these polymer powders can be re-dispersed to form an emulsion, which in turn forms continuous films within cement mortar later when the water is removed by evaporation and hydration of cement.
- vinyl esters comprise vinyl acetate, vinyl propionate, vinyl butyrate, vinyl 2-ethylhexanoate, vinyl laurate, 1-methylvinyl acetate, vinyl pivalate, and vinyl esters of alpha-branched monocarboxylic acids having from 5 to 11 carbon atoms.
- Some preferred examples include VEOVATM 5 RTM, VEOVATM 9 RTM, VEOVATM 10 RTM, VEOVATM 11 RTM (VEOVA is a trademark of Resolution Performance Products, LLC).
- Preferred methacrylic esters or acrylic esters include methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, n- butyl methacrylate, and 2-ethylhexyl acrylate.
- Preferred vinyl-aromatics include styrene, methylstyrene, and vinyltoluene.
- a preferred vinyl halide is vinyl chloride.
- the preferred olefins are ethylene and propylene, and the preferred dienes are 1,3-butadiene and isoprene.
- the RDP is obtained from vinyl ester-ethylene copolymer (also named ethylene vinyl acetate, EVA), such as FX2350 available from AkzoNobel.
- EVA ethylene vinyl acetate
- the polymer emulsion is a two phase system having finely dispersed polymeric particles in solvent such as water.
- An aqueous emulsion polymer is normally composed of emulsion polymer particles, such as vinyl polymer or polyacrylic ester copolymer and a surfactant containing hydrophobic and hydrophilic moieties.
- the preferred aqueous emulsion polymer when applied as a coating on a substrate and cured at ambient or elevated temperature, has been found to have excellent solvent, chemical and water resistance;
- the inventive mortar composition typically comprises 5% or more, and can comprise
- Early strength agent also named “accelerator” means a chemical substance mixed with cement slurry to reduce the time required for setting and hardening cement to develop sufficient compressive strength to enable demolding or drilling operations to continue.
- the early strength agent can be selected from nitrate salts (such as sodium nitrate and potassium nitrate); formate salts (such as sodium formate and calcium formate); chloride salts (such as sodium chloride, calcium chloride, and magnesium chloride); thiocyanate salts (such as sodium thiocyanate); nitrite salts (such as sodium nitrite); mono-, di- and triethanolamine; and highly alkaline agents including alkali hydroxide (such as sodium hydroxide, calcium hydroxide, and potassium hydroxide), alkali carbonate (such as sodium carbonate and potassium carbonate), alkali silicate (such as sodium silicate), and alkali aluminate (such as sodium aluminate).
- alkali hydroxide such as sodium hydroxide, calcium
- US5,605,571 also teaches an accelerator for hydraulic binders containing at least a nitrate- or sulfite component, at least a thio-cyanate component, at least an alkanolamine component and at least a carboxylic acid component.
- the early strength agent used in the inventive mortar is calcium formate.
- the inventive mortar composition typically comprises 0.1% or more, and can comprise 0.2% or more, even 0.5% or more, even 0.7% or more, and at the same time typically comprises 1.8% or less, and can comprise 1.5% or less, even 1.2% or less, even 1% or less by weight of early strength agent based on the total dry weight of the mortar composition.
- Hydrophobic agent is water repellant material incorporated into hydratable cementitious materials such as cement pastes, masonry cements, mortars, and concrete to achieve a degree of moisture impermeability.
- exemplary hydrophobic agents suitable for the inventive mortar include an aliphatic carboxylic acid or salt or ester thereof, a fatty acid or salt or the ester thereof, a natural or synthetic wax, a natural or synthetic oil, a silicone compound, a silane compound, a siloxane compound, a naphthalene compound, a melamine compound, a dicarboxylic acid or the salt thereof, or a mixture of any of the foregoing.
- hydrophobic agents are silane-based.
- Silane-based hydrophobic agents are silanes that are chemical compounds of silicon and hydrogen and consist of a chain of silicon atoms covalently bonded to each other and to hydrogen atoms. Alkyl groups could be linked to the silicon chain of a siliane-based hydrophobic agent.
- butyltrimethoxysilane and other silanes are commercially available from Dow Corning and AkzoNobel and are suitable silane-based hydrophobic agents.
- the inventive mortar composition typically comprises 0.05% or more, and can comprise 0.1% or more, even 0.2% or more, and at the same time typically comprises 0.75% or less, and can comprise 0.5% or less, even 0.3% or less by weight of hydrophobic agent based on the total dry weight of the mortar composition.
- Polymer fibers also named as “synthesized fibers", are used to reinforce or otherwise improve the properties of concrete by applying them to aqueous based concrete mixes prior to the curing of the concrete.
- the types of polymer fibers in use or proposed for use in the present invention include those composed of polyolefins, especially polypropylene, polyester, polyamide, polyacrylic and polyvinyl alcohol.
- Polymer fibers can be produced by any well known melt spinning process.
- polymer fibers are used to enhance the flexibility of the mortar.
- polymer fibers used in the inventive mortar are polypropylene fibers, such as the polypropylene fibers (8mm in length and 0.02- 0.03mm in diameter) available from Kaitai Fiber Cooperation.
- the use of polypropylene fibers is desirable for several reasons, including low raw material cost, excellent physical properties and the nonreactive properties of the polymer in the alkaline concrete mix.
- the inventive mortar composition typically comprises 0.05% or more, and can comprise 0.1% or more, even 0.2% or more, and at the same time typically comprises 0.75% or less, and can comprise 0.5% or less, even 0.3% or less by weight of polymer fibers based on the total dry weight of the mortar composition.
- Fillers are inorganic material without binding function. It includes coarse aggregate and fine filler.
- the particle size of coarse aggregate is larger with maximum size up to 8mm.
- the particle size of fine filler is smaller, generally less than 0.1mm.
- aggregate is quartz sand which usage level is high (normally greater than 40% by weight in a mortar), while one example of fine filler is calcium carbonate (CaC0 3 ) powder.
- Quartz sand generally refers to all sorts of sand with quartz content at absolute high level, such as sea sand, fluvial sand and lake sand.
- the inventive mortar composition typically comprises 50% or more, and can comprise 55% or more, even 60% or more, and at the same time typically comprises 75% or less, and can comprise 70% or less, even 65% or less by weight of fillers based on the total dry weight of the mortar composition.
- inventive mortar composition typically comprises 18% or more, and can comprise 20% or more, even 23% or more, and at the same time typically comprises 35%) or less, and can comprise 30% or less, even 27% or less by weight of Portland cement based on the total dry weight of the mortar composition.
- Portland cement has a strength grade of 42.5R according to China National Code GB 175-2007, "Common Portland Cement".
- Cellulose ether is also used in the inventive mortar for water retention and
- Suitable cellulose ethers include hydroxyalkylcelluloses (e.g., hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC) and
- HPHEC hydroxypropylhydroxyethylcellulose
- carboxy-alkylcelluloses e.g.,
- CMC carboxymethylcellulose
- carboxyalkylhydroxyalkylcelluloses e.g.,
- CHEC carboxymethylhydroxyethylcellulose
- CHPC carboxymethyl-hydroxypropylcellulose
- SEC sulphoethylcellulose
- SPC sulphopropylcellulose
- carboxyalkylsulphoalkylcelluloses e.g., carboxymethylsulphoethylcellulose
- CMSEC carboxymethylsulphopropylcellulose
- CMSPC carboxymethylsulphopropylcellulose
- hydroxyalkylsulphoalkylcelluloses e.g., hydroxyethylsulphoethylcellulose (HESEC), hydroxypropylsulphoethylcellulose (HPSEC) and hydroxyethylhyd
- HHPSEC roxypropylsulphoethylcellulose
- MHESEC methylhydroxyethylsulphoethylcellulose
- MHPSEC methylhydroxypropylsulphoethylcellulose
- MHEHPSEC methylhydroxyethylhydroxypropylsulphoethylcellulose
- alkylcelluloses e.g., methylcellulose (MC), ethylcellulose (EC)
- binary or ternary alkylhydroxyalkylcellulose e.g., hydroxyethylmethylcellulose (HEMC), ethylhydroxy ethylcellulose (EHEC)
- HPMC hydroxypropylmethylcellulose
- EHPC ethylhydroxypropylcellulose
- EHEC ethylmethylhydroxyethylcellulose
- alkenylcelluloses and ionic and nonionic alkenylcellulose mixed ethers e.g., allylcellulose, allylmethylcellulose, allylethylcellulose and carboxy-methylallylcellulose
- dialkylaminoalkylcelluloses e.g., ⁇ , ⁇ -dimethylaminoethylcellulose, N,N- diethylaminoethylcellulose
- dialkylaminoalkylhydroxyalkylcelluloses e.g., N,N- dimethylaminoethylhydroxyethylcellulose and N,N- dimethylaminoethylhydroxypropylcellulose
- arylhydroxyalkylcelluloses e.g., benzylcellulose, methylbenzylcellulose and
- the cellulose ether used in the inventive mortar is methyl hydroxyethyl cellulose, such as CP 1425 available from The Dow Chemical Company.
- the inventive mortar composition typically comprises 0.05% or more, and can comprise 0.1%> or more, even 0.2%> or more, and at the same time typically comprises 0.75%> or less, and can comprise 0.5%> or less, even 0.3%> or less by weight of cellulose ether based on the total dry weight of the mortar composition.
- the dry-mix of the inventive mortar could be obtained by mixing silica sand and fibers, cellulose ether, RDP and calcium formate for 30 seconds to obtain a mixture, and then mixing the mixture with calcium carbonate and cement for 30 seconds. Upon application, water and other liquid components could be added under stirring to obtain the inventive mortar composition.
- the sample EIFS When a sample EIFS is subjected to weathering testing, the sample EIFS should go through three circulations in order: heat/rain circulation, dry freeze-thaw circulation, and wet freeze-thaw circulation.
- Testing apparatus and equipments, sample preparation and curing, and the testing processes of heat/rain circulation and dry freeze-thaw circulation follow China Industrial Code JG149-2003 "External thermal insulation composite systems based on EPS".
- the testing processes of wet freeze-thaw circulation are specified as below.
- the sample is kept at 20 ⁇ 5 ° C and relative humidity no less than 80%> for lh.
- Water (15 ⁇ 5 ° C) is sprayed onto the sample with a spraying water volume 1.0-1.5L/(m 2 sample surface area-min) for lh.
- the sample is then placed at 20 ⁇ 5 ° C and relative humidity no less than 80% for lh.
- the surface temperature of the sample is decreased to -20 ° C within 2h, and then the sample is kept at -20 ⁇ 5 ° C for 7h.
- the sample is heated to 20 ° C again to complete one cycle.
- the sample should experience five cycles in series without interruption.
- a comparison test was designed for testing the impact resistance and compressive strength/flexural strength of sample EIFS made from different basecoat mortars.
- a sample EIFS was prepared following JG149-2003.
- the insulation board used in the sample EIFS is STYROFOAMTM XPS extruded polystyrene board (STYROFOAM is a trademark of Dow Chemical) with a density of 30kg/m 3 .
- An adhesive mortar meeting the requirement of JG149-2003 was used to adhere the insulation board onto a wall in the testing equipment.
- Such adhesive mortar comprises 34% 42.5R Portland cement, 62.9% silica sand, 2.6% EVA, 0.2% methyl hydroxyethyl cellulose (viscosity 35000-45000 mPa-s) and 0.3%) calcium formate.
- the basecoat mortar was then applied onto the insulation board.
- basecoat mortars Components used in basecoat mortars are listed in Table 1 as below.
- the dry-mix of the inventive mortar was obtained by mixing silica sand and fibers, cellulose ether, RDP and calcium formate for 30 seconds to obtain a mixture, and then mixing the mixture with calcium carbonate and cement for 30 seconds.
- Examples HT1, HT4 and HT5 have a RDP fraction of 6-8.5 wt.% and represent inventive mortars.
- Examples HT2, HT3 and HT6 are comparative examples.
- Table 2 Formulations and performance test results for EIFS samples (unless otherwise indicated, values are in units of wt.% relative to total dry weight of a mortar composition.)
- hydrophobic agent seal 80 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
- inventive mortars HT1, HT4 and HT5 achieve a ratio of compressive strength to flexural strength less than 3.0 while keeping impact resistance greater than 3 joules thereby meeting the requirement of JG149-2003.
- HT2 has a lower dosage RDP than inventive mortars and could not keep workable impact resistance.
- HT3 and HT6 have higher dosage RDP than inventive mortars but the mortar samples are too soft and are not suitable for EIFS application.
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Abstract
La présente invention concerne une composition de mortier utilisée dans un système de finition d'isolation extérieure contenant de 20 % à 35 % en poids de ciment Portland, de 55 % à 70 % en poids de charges, de 0,05 % à 0,5 % en poids d'éther de cellulose, de 6 % à 8,5 % en poids de poudre de polymère redispersible et/ou émulsion de polymère, de 0,05 % à 0,5 % en poids d'un agent hydrophobe, de 0,05 % à 0,5 % en poids de fibres de polymère, et de 0,2 % à 1,5 % en poids d'agent de prise rapide, les pourcentages étant sur la base du poids sec total de ladite composition de mortier.
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PCT/CN2011/081560 WO2013063743A1 (fr) | 2011-10-31 | 2011-10-31 | Mortier haute performance pour système de finition d'isolation extérieure |
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Cited By (17)
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CN104529329A (zh) * | 2014-12-11 | 2015-04-22 | 德清扬泰建筑材料有限公司 | 一种防火外墙干粉砂浆 |
CN104529355A (zh) * | 2015-01-20 | 2015-04-22 | 佛山市托肯建材有限公司 | 一种干粉弹性拉毛砂浆及制造方法 |
CN104829196A (zh) * | 2015-04-17 | 2015-08-12 | 上海英硕聚合材料股份有限公司 | 一种气凝胶改性的无机保温砂浆及其使用方法 |
CN104876492A (zh) * | 2015-05-27 | 2015-09-02 | 湖北嘉德普安涂料有限公司 | 一种用于柔美软石成品贴的粘结砂浆 |
CN105174875A (zh) * | 2015-10-15 | 2015-12-23 | 重庆富皇混凝土有限公司 | 一种高流动性泵送陶粒混凝土及其制备方法 |
CN105859218A (zh) * | 2016-04-14 | 2016-08-17 | 广西横县恒丰建材有限责任公司 | 预拌机械化喷涂砂浆及其生产方法 |
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CN104529329A (zh) * | 2014-12-11 | 2015-04-22 | 德清扬泰建筑材料有限公司 | 一种防火外墙干粉砂浆 |
CN104529355A (zh) * | 2015-01-20 | 2015-04-22 | 佛山市托肯建材有限公司 | 一种干粉弹性拉毛砂浆及制造方法 |
CN104829196A (zh) * | 2015-04-17 | 2015-08-12 | 上海英硕聚合材料股份有限公司 | 一种气凝胶改性的无机保温砂浆及其使用方法 |
CN104876492A (zh) * | 2015-05-27 | 2015-09-02 | 湖北嘉德普安涂料有限公司 | 一种用于柔美软石成品贴的粘结砂浆 |
CN105174875B (zh) * | 2015-10-15 | 2017-05-17 | 重庆富皇混凝土有限公司 | 一种高流动性泵送陶粒混凝土及其制备方法 |
CN105174875A (zh) * | 2015-10-15 | 2015-12-23 | 重庆富皇混凝土有限公司 | 一种高流动性泵送陶粒混凝土及其制备方法 |
WO2017071722A1 (fr) * | 2015-10-29 | 2017-05-04 | Knauf Gips Kg | Mortier de scellement minéral |
CN105859218A (zh) * | 2016-04-14 | 2016-08-17 | 广西横县恒丰建材有限责任公司 | 预拌机械化喷涂砂浆及其生产方法 |
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CN106007573A (zh) * | 2016-05-23 | 2016-10-12 | 广西横县恒丰建材有限责任公司 | 超细高强塑性膨胀压浆料及其生产方法 |
CN106007592A (zh) * | 2016-05-23 | 2016-10-12 | 广西横县恒丰建材有限责任公司 | 超早强型塑性膨胀修补砂浆及其生产方法 |
CN106673490A (zh) * | 2016-12-01 | 2017-05-17 | 深圳中凝科技有限公司 | 一种气凝胶板及其制备方法 |
CN111302722A (zh) * | 2018-12-11 | 2020-06-19 | 北京海普斯建材有限公司 | 一种聚合物抗裂砂浆 |
CN111747706A (zh) * | 2020-06-17 | 2020-10-09 | 北京金中洲建筑材料有限公司 | 一种抗裂干混砂浆及其生产工艺 |
CN112159175A (zh) * | 2020-09-29 | 2021-01-01 | 江苏尼高科技有限公司 | 一种双组分保温砂浆、制备方法及其保温构造 |
WO2024149782A1 (fr) | 2023-01-11 | 2024-07-18 | Saint-Gobain Isover | Élément isolant et son procédé de fabrication |
CN116891371A (zh) * | 2023-09-11 | 2023-10-17 | 高密市东泰建材有限公司 | 一种早强型铺装砂浆及其制备方法 |
CN116891371B (zh) * | 2023-09-11 | 2023-11-24 | 高密市东泰建材有限公司 | 一种早强型铺装砂浆及其制备方法 |
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