WO2014083579A1 - Composition pour des mortiers de maçonnerie - Google Patents

Composition pour des mortiers de maçonnerie Download PDF

Info

Publication number
WO2014083579A1
WO2014083579A1 PCT/IN2013/000717 IN2013000717W WO2014083579A1 WO 2014083579 A1 WO2014083579 A1 WO 2014083579A1 IN 2013000717 W IN2013000717 W IN 2013000717W WO 2014083579 A1 WO2014083579 A1 WO 2014083579A1
Authority
WO
WIPO (PCT)
Prior art keywords
composition
weight
group
filler mixture
present disclosure
Prior art date
Application number
PCT/IN2013/000717
Other languages
English (en)
Inventor
Pradeep Vasant Joshi
Shilpa Pradeep Joshi
Original Assignee
Pradeep Vasant Joshi
Shilpa Pradeep Joshi
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pradeep Vasant Joshi, Shilpa Pradeep Joshi filed Critical Pradeep Vasant Joshi
Publication of WO2014083579A1 publication Critical patent/WO2014083579A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • 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
    • 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
    • C04B28/24—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 alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • 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 disclosure generally relates to masonry. More particularly, the present
  • Masonry broadly relates to building structures from individual units, bound together by mortar.
  • cement-sand-water mixture has been used as mortar in the construction process.
  • Cement is a conventional binder that sets and hardens independently and even binds together the other constituents of the construction material.
  • the process of manufacture of cement is, highly detrimental to the environment due to various types of emissions such as carbon dioxide and heavy metal emissions.
  • cement needs to be cured to ensure strength and hardness.
  • the temperature and moisture of the cemented region needs to be controlled. This is achieved by spraying or ponding the surface with water.
  • this process leads to a huge wastage of water and thus an effective alternative should be suitably conceived.
  • Sand which is commonly used for construction purposes may : be . procured from different sources such as pits, rivers and sea. However, the continuous recovery of sand from such environmental sites becomes deleterious to the ecology and ecosystem as the natural balance of components becomes uneven.
  • United States Patent Application No. 20120160131 and United States Patent No. 5,346,548 disclose the use of specific cementcompositions comprising a variety of biowaste ash such as agricultural waste ash, municipal waste ash, animal waste ash and siliceous ash from crop residue, for subterranean formations.
  • biowaste ash such as agricultural waste ash, municipal waste ash, animal waste ash and siliceous ash from crop residue, for subterranean formations.
  • Portland cement is an essential part of the composition, it mars the overall purpose behind the use of other ecofriendly constituents.
  • United States Patent Application No. 20080153942 and European Patent Application No. 1932814 disclose a new composition of polymeric concrete that comprises polymerization or polycondensation resin, mechanical resistance elements, catalysts and heavy metals. However, these new compositions of polymeric concrete take prolonged setting time.
  • Our Indian Patent No. 253002 (also published as WO2009007994) 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 bonder, water, fillers and one or more additives.
  • the composition disclosed in the abovementioned application is a ready to use material and hence the consistency and homogeneity of the material is assured.
  • the required bond strength of the mortar has not been achieved when low viscosity vinyl acetate and fly ash were employed in the composition.
  • compositions suitable for use in the building construction industry comprise water, binders, and fillers such as silica, bottom ash, stone grit, and thickeners, pH stabilizers, coalescing agent and other additives.
  • the compositions as disclosed in the abovementioned patent applications are ready to use material and demonstrate excellent bond strength, improved adhesion, thickening and application behavior.
  • the effect of particle size distribution of various fillers used and the effect of chemical constituents thereof on the performance of the mortar compositions for various applications has not been disclosed in the above mentioned Indian patent applications.
  • Another object of the present disclosure is to provide a composition for masonry applications.
  • Still another object'bf the present disclosure is to provide a composition for masonry applications which is environment friendly and economical.
  • a yet another object of the present disclosure is to provide a composition for masonry applications which saves time and labor.
  • composition for masonry applications comprising:
  • At least one binder dry solid weight
  • a filler mixture in an amount ranging between 25 % and 90 % by weight, .wherein the combined filler mixture contains Al 2 O 3 in the range of 1 % to 30 % by weight, Si0 2 in the range of 12 % .to 84 % by weight and CaO in the range of 1 % to 30 % by weight, all proportions being with respect to the total mass of the composition;
  • the binder includes at least one binder selected from the group consisting of polyurethane, epoxy resin, rosin resin, alkyd resin, vinyl -acetate monomer based emulsion, emulsion of vinyl acetate monomer and vinyl ester of versatic acid (VAM- VEOVA), pure acrylic emulsion, styrene acrylic emulsion, cashew nut shell liquid (CNSL), styrene butadiene rubber emulsion, agro based polymers, and silicate solution of sodium, potassium, calcium and aluminum.
  • binder selected from the group consisting of polyurethane, epoxy resin, rosin resin, alkyd resin, vinyl -acetate monomer based emulsion, emulsion of vinyl acetate monomer and vinyl ester of versatic acid (VAM- VEOVA), pure acrylic emulsion, styrene acrylic emulsion, cashew nut shell liquid (CNSL), styrene butadiene rubber
  • the amount of binder varies between 1 and 14 %, preferably 2 % and 8 % by weight of the total mass of the composition.
  • the combined filler mixture contains Al 2 O 3 in the range of 2 to 14%, SiO 2 in the range of 24 % to 54 % and CaO in the range of 1 % to 23 % by weight of the total mass of the composition.
  • the molar ratio of CaO SiO 2 ranges between 1:0.6 and 1.1:19, preferably between 1:1.7 and 1:15.
  • the combined filler mixture further comprises at least one constituent selected from the group consisting of oxides of iron, magnesium, manganese oxide, titanium and sodium.
  • the filler mixture comprises fillers selected from the group consisting of volcanic ash, fly ash, slag, gypsum, dolomite, calcium hydroxide and crystalline silica.
  • the filler mixture comprises ash selected from the group consisting of • volcanic ash and fly ash in an amount of 0 to 62 % by weight of the total mass of the composition.
  • the filler mixture comprises crystalline silica selected from the group consisting of desert silica, marine silica, quarry silica, foundry silica, any kind of recycled silica and combinations thereof, said silica being present in an amount of 0 to 70 % by weight of the composition.
  • the filler mixture comprises gypsum in an amount of 0 to 32 % by weight of the composition.
  • the filler mixture comprises slag in an amount of 0 to 75 % by weight of the composition.
  • the filler mixture further includes at least one filler selected from the group consisting of agro-fillers, silicates of sodium, calcium and aluminum, chalk, talc, rubber shredding, EPS-waste, perlite, vermiculite and zirconium.
  • agro-fillers silicates of sodium, calcium and aluminum, chalk, talc, rubber shredding, EPS-waste, perlite, vermiculite and zirconium.
  • the agro filler is selected from the group consisting of rice husk, sugarcane waste, coconut shredding, coir, banana leaves and dry biomass shredding.
  • the filler mixture comprises fillers having particle size distribution ranging between . 1 micron , and 4000 microns, preferabl , between 45 micron and 4000 microns.
  • the property modifier includes at least one modifier selected from the group consisting of rheology modifiers, pH stabilizers, preservatives, silicone additives and solvents.
  • the property modifier includes at least one rheology modifier selected from the group consisting of hydroxylethylcellulose (HEC), carboxymethylcellulose (CMC), methylhydroxyethyl cellulose (MHEC), hydrophobically modified alkali sellable emulsions(HASE) and hydrophobically modified ethoxylated urethanes (HEUR) and alkali soluble emulsions.
  • the property modifier includes at least one pH stabilizer selected from the group consisting of ammonia and urea solution, said pH stabilizer being present in an amount ranging between 0.0% and 3.0 % by weight of the total mass of the composition.
  • the property modifier includes at least one preservative selected from the group consisting of aqueous isothiazolinones, carbamates and biurates; said preservative being present in an amount ranging between 0.0 % and 2.0 % by weight of the total mass of the composition.
  • the property modifier includes at least one additive selected from the group consisting of wax, wax emulsions, silicone oils and silicone waxes.
  • the property modifier includes at least one solvent selected from the group consisting of texanol, garasol, diethylene glycol and pine oil.
  • composition of the present disclosure further comprising at least one additive selected from the group consisting of de-foaming agents and wetting dispersing agent.
  • the disadvantages allied with the conventional cement-sand-water mixture and with the substitutes thereof as disclosed in the above described prior art and other related prior art references are overcome in the present disclosure by providing a green composition that mainly employs waste materials obtained from various natural and industrial resources thereby preserving the natural resources, avoiding the use of eco- toxic constituents and also facilitating the disposal of waste products and materials. Further, the composition of the present disclosure also obviates the use of water for curing purpose thereby promoting judicial use of water.
  • the green composition is completely free from Portland cement and river based sand and is particularly designed to partially or completely substitute the cement-sand- water mortars used in the construction process.
  • a green composition for application in the masonry sector said composition comprising at least one binder, at least one filler, a least one property modifier and water.
  • Water in the composition of the present disclosure is mainly utilized as a medium of operation and for workability. It serves to adjust the consistency of the composition and acts as a thinner to adjust application properties such as spreadability and coverage.
  • the amount of water may be varied according to the desired application.
  • the amount of water in the composition of the present disclosure varies between 5 % and 55 % by weight of the total mass of the composition.
  • the binders useful for the composition of the present disclosure include polymer based binders.
  • the binders are aqueous in nature and may be present in the form of a solution or an emulsion.
  • the selection and choice of binders useful for the composition of the present disclosure basically depends on the properties as desired in the product such as hardness, flexibility, setting time,* shelf life, availability and cost effectiveness.
  • polymer based binders suitable for the composition of the present disclosure include, but are not limited to, polyurethane, epoxy resins, rosin based emulsions, alkyd resins, vinyl acetate monomer based emulsion (VAM), emulsion of viriyl acetate monomer 'and vinyl ester of versatic acid ( VA M- VEO VA), pure acrylic - emulsion, styrene acrylic emulsion, cashew nut shell liquid (CNSL) modified emulsion, styrene butadiene rubber and agro based polymers derived from a variety of agro-wastes by extraction of lignin.
  • PLAM vinyl acetate monomer based emulsion
  • VA M- VEO VA emulsion of viriyl acetate monomer 'and vinyl ester of versatic acid
  • pure acrylic - emulsion styrene acrylic emulsion
  • CNSL cashew
  • some other examples of binders include, but are not limited to, silicate solutions of sodium, potassium, calcium and aluminum.
  • the amount of the binder (dry solid content) in the composition of the present disclosure typically ranges between 1 % and 25 % by weight of the total mass of the composition. In accordance with one of the embodiments of the present disclosure, the amount of binder (dry solid content) ranges between 1% and 14 % by weight of the total mass of the composition. In accordance with another embodiment of the present disclosure, the amount of binder (dry solid content) ranges between 2 % and 8% by weight of the total mass of the composition.
  • binders used in the composition of the present disclosure give elasticity to the composition after drying and also act as strong: adhesive films to hold together bricks and blocks. In wet conditions, binders act as vehicles to hold other solid particulate fillers in a homogeneous dispersed form. Binders also act as binders for forming a homogeneous and continuous film of fillers embedded in the binder film.
  • the composition of the present disclosure comprises a filler mixture.
  • the "fillers" in the context of the present disclosure refers to a non-reactive material which is suitably used in the present composition to provide desirable properties to the composition such as bulk, high mechanical strength, good compaction, water resistance property and the like.
  • the inventors of the present disclosure emphasizes on using selective industrial wastes and byproducts as fillers such as waste from thermal power plants, impurities generated during extraction and purification of metal oxides, agro- wastes and the like.
  • the filler mixture in the composition of the present -disclosure is -typically chosen* as a source for the following constituents: oxides, sulfates and carbonates of calcium, silicates and oxides of aluminum, silica and oxides of iron, magnesium and titanium.
  • the constituents as herein above described are available from a number of raw materials suitably working as fillers for the purpose of the present disclosure.
  • the inventors of the present disclosure advantageously, use a number of fillers such as mineral fillers, agro fillers, synthetic fillers as a filler mixture.
  • mineral fillers suitable for the purpose of the present disclosure include, but are not limited to, ash, for example, volcanic ash, fly ash, pond ash, fumed silica, foundry silica, agro waste ash, and crystalline silica, for example, desert silica, marine silica,quarry silica, foundry silica and any kind of recycled silica, and gypsum, slag, chalk, talc, perlite, vermiculite, zirconium and the like.
  • ash for example, volcanic ash, fly ash, pond ash, fumed silica, foundry silica, agro waste ash, and crystalline silica, for example, desert silica, marine silica,quarry silica, foundry silica and any kind of recycled silica, and gypsum, slag, chalk, talc, perlite, vermiculite, zirconium and the like.
  • agro fillers suitable for the purpose of the present disclosure include, but are not limited to, rice husk, sugarcane trash, any other waste from agro base, coconut shavings, coir, banana leaves or any part of banana and dry biomass shredding.
  • Some other examples of fillers include, but are not limited to, slag-from metal extraction industry, gypsum-as byproduct of industries, expandable polystyrene (EPS)-waste from packaging industry, calcium hydroxide, silicates of sodium, calcium, potassium and aluminum, and rubber shredding from rubber recycling.
  • EPS expandable polystyrene
  • the volcanic ash used as one of the fillers in the composition of the present disclosure is obtained from volcanic eruptions.
  • the volcanic ash is mainly composed of igneous materials and shows hardness of +5 on the Mohs scale. Chemically, the volcanic ash contains silica, iron oxide, calcium oxide, titanium oxide magnesium oxide, sodium oxide, calcium sulfate salts, aluminum oxides, silicates of magnesium and aluminum, and the like.
  • the fly ash may be obtained from various other sources.
  • Gypsum is obtained from gypsum deposits available across the world as well as from marine water deposits. Naturally available gypsum may also be used in the composition as a prominent filler-binder material. Gypsum is also available as phosphogypsum, a by-product in the phosphoric acid- industry. The- gypsum used hr the composition of the present disclosure acts as a main source of calcium in the formation of the cement-sand- water film.
  • Slag a nonmetallic product, consists of silicates and alumino-silicates of calcium andother bases. It is a collection of compounds that are removed from the ferrous and non-ferrous smelting processes. Significantly, ground, granulated slag reacts with water to produce cement-like properties. Slag typically comprises silicon dioxide, aluminum oxide, calcium oxide, magnesium oxide, alkalies, iron oxide and the like. The compositional details of some of the fillers used in the composition of the present disclosure are tabulated in Table- 1.
  • the filler mixer in accordance with the present disclosure comprises fillers in various combinations. Further to the combinations of fillers, the inventors of the present disclosure have advantageously optimized the weight proportion of fillers used in the filler mixture so as to achieve compositions having constituents in the desired ratio.
  • the weight proportion of various constituents in the combined filler mixture ranges as follows: Al 2 O 3 in the range of 1 to 30 %r SiO 2 in the range of l-2 % to 84 ⁇ % ⁇ , and CaO in the range of 1 % to 30 %.
  • the weight proportion of other constituents in the combined filler mixture varies as follows: Fe 2 O 3 : 0.6 to 10 %; MgO: 0.1 to 10.05 %; Mn 2 O 3 : 0.1 to 0.14 %; Na 2 O: 0.0 to 2.74 %; and TiO 2 : 0.0 to 10 %. All weight proportions of the constituents are based On 100 % mass of the composition.
  • the ratio of CaO to SiO 2 in the composition of the present disclosure ranges between 1:0.6 and 1.1:19. In accordance with one of the embodiments of the present disclosure, the ratio of CaO to SiO 2 ranges between l:1.5and 1:17.
  • the inventors of the present disclosure also emphasizes on using fillers with various particle size distributions (see Table-2) so as to achieve good compaction and surface coverage thereby improving the applicability of the composition, shelf life and water resistance property.
  • the average particle size distribution of various fillers . used in the composition of the present disclosure typically ranges between 2 micron and 4000 micron. In accordance with one of the embodiments of the present disclosure, the particle size distribution of fillers ranges between 45 microns and 4000 micron.
  • the proportion of various sized particles of fillers in the composition of the present disclosure depends upon the flow/viscosity of each composition and its application in the construction industry.
  • the filler mixture in the composition of the present disclosure is suitably used in varying proportions.
  • the amount of the filler mixture in the present composition usually ranges between 25 % and 90 % by weight of the total mass of the composition.
  • the inventors of the present disclosure have also optimized the weight proportion of various fillers used in the filler mixture so as to achieve compositions having constituents in the desired ratio. .
  • the filler mixture comprises ash selected from group consisting of volcanic ash and fly ash.
  • the amount of ash in the filler mixture ranges between 0% and 62 % by weight of the composition.
  • the filler mixture comprises crystalline silica.
  • the crystalline silica includes at least one silica selected from the group consisting of desert silica, marine silica, quarry silica, foundry silica and any kind of recycled silica.
  • the amount of crystalline silica typically ranges between 0 % and 70 % by weight of the composition.
  • the filler mixture comprises gypsum.
  • the amount of gypsum typically ranges between 0 % and 32 % by weight of the composition.
  • the filler mixture comprises slag.
  • the amount of slag in the composition of the present disclosure typically ranges between 0 % and 75 % by weight of the composition.
  • composition of the present disclosure further comprises at least one property modifier.
  • the property modifiers are usually added to modify the composition's property.
  • the property modifiers used in the composition of the present disclosure include a broad range of modifiers including, but not limiting to, rheology modifiers, pH stabilizers, preservatives, silicone additives and solvents.
  • the rheology modifiers are used to optimize the flow property (viscosity) of -ther composition, for good shelf life and pack stability and also for good spreadability.
  • the rheology modifiers used in the composition of the present disclosure may be synthetic modifiers or natural modifiers.
  • Examples of natural rheology modifiers suitable for the purpose of the present disclosure include, but are not limited to, hydroxyl ethyl cellulose (HEC), carboxy methyl cellulose (CMC), methyl hydroxyl ethyl cellulose (MHEC) and combinations thereof.
  • Examples of synthetic modifiers include, but are not limited to, alkali swellable emulsions (ASE), hydrophobically modified alkali swellable emulsions (HASE), hydrophobically modified ethoxylated urethanes (HEU ) and the like. These modifiers may be used independently or in combinations to obtain the desired flow property.
  • the amount of rheology modifiers in the composition of the present disclosure usually ranges between 0 % and 3.0 % by weight of the total mass of the composition.
  • the pH stabilizer used in the composition of the present disclosure typically includes ammonia.
  • ammonia stabilizer helps in retaining the stability of the polymer compositions throughout its shelf life.
  • some amine compounds can also be used as pH stabilizers.
  • the use of an additional amine depends largely on the specification of the rehology modifier used in the composition of the present disclosure.
  • the gel formation of the rheology modifier takes place under alkaline medium usually at a pH of 8 to 10.
  • the composition of the present disclosure shows alkaline pH upon addition of the filler mixture, hence the use of pH stabilizer in the composition of the present disclosure depends mainly on the pH of the composition at the time of addition of the rheology modifier.
  • the amount of the pH stabilizer used in the composition of the present disclosure typically ranges between 0 % and 3% * by weight of the total mass of the composition: - " - -> - ⁇
  • composition in accordance with the present disclosure may also comprise a buffer solution to maintain the pH of the composition during its shelf life.
  • buffer solution in accordance with the present disclosure is a urea solution.
  • Preservatives are agents that are used for controlling the bacterial and fungal growth during the shelf life of the product as well as after its application. Any conventionally known preservative can be suitably used in the present composition. Examples of preservatives suitable for the purpose of the present disclosure include, but are not limited to aqueous isothiazolinones, carbamates, biurates and the like. The amount of preservatives used in the composition of the present disclosure ranges between 0 % and 2% by weight of the total mass of the composition.
  • Silicone additives such as wax, wax emulsions, silicone oils and silicone waxes are also included in the composition of the present disclosure to improve the water resistance property of the composition and also to reduce the surface tension of the applied film so that further defects of the coating maybe eliminated.
  • the silicone additives are added in an amount ranging between 0% and 3% by weight of the composition.
  • the composition of the present disclosure also comprises at least one solvent to facilitate the uniform film formation, applicability of the composition and to dry it once the composition is applied.
  • the solvents are typically used as coalescing agents, hence any coalescing agent may be suitably r used in the composition of the present disclosure.
  • Examples of solvents suitable for the purpose of the present disclosure include, but are not limited to, texanol, garasol, diethylene glycol and the like. The solvent is typically added in a very less quantity.
  • the composition of the present disclosure' may also comprise additives that include, but are not limited to, de-foamers, wetting dispersing agents and the like.
  • Wetting dispersing agents may be used upon the nature of the fillers used and their particle size distribution. The wetting agents facilitate the wetting of the particles and enable the complete surface area of each particle to bond with the polymers, thus enabling proper functioning of the composition.
  • the de-foamers are typically added in case of formation of foam in the composition, due to incorporation of air during mixing or due to the action of rheology modifiers.
  • the amount of de-foamers typically added in the composition of the present disclosure ranges between 0 % and 1% by weight of the total mass of the composition.
  • the proportion of various ingredients such as binder, filler mixture, rheology modifier and water in the composition of the present disclosure may vary according to the purpose for which it is applied.
  • the present disclosure provides a composition suitable as a masonry bonding adhesive which comprises binder in an amount ranging between 3 % and 8 %; filler mixture in an amount ranging between 62 % and 75 %; rheology modifier in an amount ranging between 0.2 % and 0.8 %. All the weight proportions are based on the total mass of the composition.
  • the present disclosure provides a composition suitable as a coarse filling mortar in masonry gaps, as a filling material to patch up electrical work in masonry and as a plasters which comprises binder in an amount ranging between 3-> % and 10 %; filler mixture in an amount ranging between 60 % and 78 %; rheology modifier in an amount ranging between 0.2 % and 0.6 %. All the weight proportions, are based on the total mass of the composition.
  • the present disclosure provides a composition suitable as a plastering mortar which comprises binder in an amount ranging between 3 % and 8 %; the filler mixture in an amount ranging between 65 % and 75 %; rheology modifier in • an° amount ranging- between 0:2 % and 0.8%. All t e ⁇ weight proportions are based on the total mass of the composition.
  • the present disclosure provides a composition suitable as a patch work repair mortar on RCC beams, columns, walls, window covings and the like which comprises binder in an amount, ranging between 2 % and 8%; the filler mixture in an amount ranging 65 % and 78 %; and rheology modifier in an amount ranging between 0.2 % and 1.0 %. All the weight proportions are based on the total mass of the composition.
  • the present disclosure provides a composition suitable as a crack filling mortar in hair line cracks on plasters which comprises binder in an amount ranging between 8 % and 15 %; the filler mixture in an amount ranging between 62 % and 75 %; rheology modifier in an amount ranging between 0.6 % and 1.6 %. All the weight proportions are based on total mass of the composition.
  • the weight proportion of the solvent in the compositions as herein above described which are suitable as a masonry bonding adhesive, as a coarse filling mortar in masonry gaps, as a plastering mortar and as a patch work repair mortar on RCC beams, columns, walls and window covings typically ranges between 0 % and 0.3 % by weight of the total mass of the composition.
  • composition for masonry application in accordance with the present disclosure may be prepared by using any conventional mixing methods, particularly the methods as disclosed in our co-pending Indian patent applications Nos. 2607/MUM/2009 and 3267/MUM/2010, the entire contents of which are hereby incorporated herein by reference.
  • composition in accordance with the present disclosure is a homogenous paste and is used for miscellaneous applications that include their use as a mortar, plaster, crack -flilerrrepair mortar in various stages of 1 construction and the ike. After application'of— these compositions on the desired surface, they start losing water by evaporation. The polymer starts drying and turns into a non degradable film. The film contains various additives and fillers which help in rendering the desired strength to the film. Further, the composition of the present disclosure provides numerous advantages over the conventional construction compositions.
  • composition of the present disclosure makes curing of the construction site with water is completely eliminated, due to the absence of cement in the composition, thus saving the water used in the construction activity, Further, the mortar bonds formed are extremely strong, water retardant, crack free and sustainable. Even further, the composition of the present disclosure makes the construction process easy, free from supervision and of consistent quality. It saves an important natural resource such as water, while employing wastes and pollutants for, construction purposes. The composition also helps in reducing time, labor and money in the construction process. Still further, the composition is a ready to use wet mix paste made with the specific ingredients in various ratios and water is used as a medium of mixing, which eliminates onsite mixing, thus ensuring the quality of mortar. The composition of the present disclosure saves water, labor, time and consequently money.
  • the composition has all the properties that are desired in any mortar for such purposes and is comparable in quality with the cement mortars. Therefore, the advantages of this composition include reduction in carbon footprint, saving water, labor, time and energy and efficient disposal of wastes, while adding value to the quality of construction by offering crack free and durable construction at reduced cost.
  • compositions for masonry applications as shown in tables 3, 4 various ingredients other than fillers such as binder, rheology modifier, medium and additives were mixed at room temperature in a stainless steel high speed mixture at speed of 1200 to 1400'rpm to obtain a first concentrate.
  • the obtained first concentrate was transferred to ⁇ a pug mixer.
  • fillers were incorporated.
  • the obtained resultant mixture was then mixed at a speed of 40 to 60rpm to obtain a homogenous mixture suitable for masonry applications.
  • all the liquid and solid ingredients are added to the pan mixer, similar to concrete mixer and mixed at a speed of 400 to 700 rpm to obtain the composition.
  • compositions of examples 1 to 49 were evaluated for the following properties:
  • Bond strength a) The bond strength of the compositions of examples 1-49 was measured in accordance with IS 15477-2004.
  • a mortar layer of 1.5 mm thickness was applied on one surface of a burnt clay brick.
  • "Another clay brick was bonded to the burnt clay brick surface having the mortar layer.
  • the two bricks were placed on a table to maintain a cantilever position.
  • the two bricks were left for curing for test purpose for 28 days and 120 days without disturbing the mortar layer.
  • the tensile strength was checked by hanging an initial weight to one end of the clay brick. This initial weight was increased until the bond between the two bricks broke. It was observed, through the bond survived the tensile strength bonding strength test, the clay brick broke.
  • the bond strength of 3N/mm 2 is considered as standard value for a cement mortar cured for 28 days. Hence compositions with at least 3N/mm 2 bond strength were considered to have satisfactory bond strength.
  • compositions of example 1-49 was measured as follows: a) In accordance with IS 5512-1983 method.
  • compositions of examples 1-49 were kept separately in an open container and their viscosity /flowability was measured. The container was then left open and the viscosity of the sample was checked after specific time intervals. The . time interval where the flow property is lost is recorded as the pot life. The pot life of the compositions of example 1-49 is marked as ok if the compositions are in standard condition after 8-10 hours when the compositions are kept in an open pot. ;
  • compositions of example 1-49 were applied separately in the form of a thin layer of 1 mm and cured for 3 days in an oven at 60°C. The samples were then subjected to wet scrub resistance to check the number of cycles passed without the bonding of the composition with the surface. The wet scrub resistance was considered as a parameter to estimate resistance to water.
  • the compositions that passed 100 cycles were found to be satisfactory for market application. However the compositions passing higher cycles were considered more satisfactory if the sample fulfilled other parameters of pot life, shelf life, applicability, spreadability and bond strength.
  • Samples of each of the compositions of example 1-49 were applied separately on a glass panel in the form of a thin layer of 3mm. The samples were then dried naturally. Thereafter, the dried samples were pricked by a pin to see their penetration. The time when the pin can not be penetrated is recorded as setting time.
  • Density is measured with a standard density cup and is recorded as weight /ltr.
  • Viscosity or the flow of the compositions of examples 1-49 is tested by the table flow meter as follows:
  • compositions of example 1-49 were taken separately and allowed to flow on a table top from a semicircular container of a specific diameter.- The spreadability of the samples on the table top was measured on the scale.
  • Table-3a Compositions for masonry applications:
  • Table-3b Compositions for masonry application:
  • compositions as tabulated in Tables 3a, 3b and 3c are evaluated and found to ranges as follows:
  • Compositions that varied with at least one property of the above list are shown in Tables 4a, 4b and 4c. These compositions have been successful in giving adequate bonding. Variation in properties is mostly with respect to shelf life, pot life and setting time. Due to large experimental data, the experiments are divided into tables 4a, 4b and 4c.
  • Table-4a Compositions for masonry applications:
  • Table-4b Compositions for masonry applications:
  • Table-4c Compositions for masonry applications:
  • compositions as tabulated in Tables 4a, 4b and 4-c demonstrate good bond strength i.e. > 3 n/mm (equivalent to cement mortar bond strength).
  • Other properties such as density, viscosity, solid content and drying time are also found to be similar to the properties of the compositions as tabulated in Tables 3a, 3b and 3c except the applicability or shelf life or pot life.
  • a composition that uses eco-friendlyconstituents and is essentially free from the Portland-cement and • A composition where most of the constituents utilized for productive purposes are byproducts, wastes and pollutants of various industries thus facilitating waste disposal as well as energy saving.

Landscapes

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

Abstract

La présente invention concerne une composition appropriée pour des applications de maçonnerie qui comporte au moins un liant, un mélange de charges, au moins un agent de modification de propriété et de l'eau. Le mélange de charges utilisé dans la composition de la présente invention comporte les charges qui sont utilisées comme source pour les constituants suivants : Al2O3, SiO2 et CaO. La composition de la présente invention est exempte de ciment, écologique et se présente sous une forme prête à l'emploi.
PCT/IN2013/000717 2012-11-27 2013-11-27 Composition pour des mortiers de maçonnerie WO2014083579A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN3376MU2012 2012-11-27
IN3376/MUM/2012 2012-11-27

Publications (1)

Publication Number Publication Date
WO2014083579A1 true WO2014083579A1 (fr) 2014-06-05

Family

ID=50827263

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IN2013/000717 WO2014083579A1 (fr) 2012-11-27 2013-11-27 Composition pour des mortiers de maçonnerie

Country Status (1)

Country Link
WO (1) WO2014083579A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104478350A (zh) * 2014-11-19 2015-04-01 海南大学 水产增养殖和海洋生态工程用防海水侵蚀水泥的制备方法
CN107216093A (zh) * 2017-06-20 2017-09-29 武汉理工大学 一种界面增强轻质混凝土及其制备方法
CN108975753A (zh) * 2018-08-23 2018-12-11 江苏申御特种建材有限公司 一种改性氧化钙类水泥混凝土膨胀剂及其制备方法
CN109021688A (zh) * 2018-07-27 2018-12-18 郑州汉东科技有限公司 一种环保水性印刷油墨及其制备方法
WO2020183429A1 (fr) * 2019-03-14 2020-09-17 Green Build Products India Pvt.Ltd. Composition de mortier et procédé pour sa préparation
CN112830707A (zh) * 2019-11-25 2021-05-25 泰州普利策新材料科技有限公司 一种与eps配合使用的改性母液及制备方法
CN113150661A (zh) * 2021-03-26 2021-07-23 湛江宝钢新型建材科技有限公司 一种铁水脱硫渣基水性底面合一防腐涂料及其制备方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000031174A1 (fr) * 1998-11-23 2000-06-02 W.R. Grace & Co.-Conn. Ouvrabilite et temps d'emploi ameliores dans un mortier de maçonnerie et procede de fabrication correspondant
RU2303581C2 (ru) * 2005-07-20 2007-07-27 Закрытое акционерное общество "Союзтеплострой" Способ получения кладочного раствора для футеровки тепловых агрегатов, преимущественно, в цветной металлургии
CN101337784A (zh) * 2008-08-14 2009-01-07 武汉理工大学 一种建筑砂浆及其制备方法
CN102276200A (zh) * 2011-05-26 2011-12-14 太原理工大学 废弃纺织纤维砌筑砂浆的制作方法
WO2012073258A2 (fr) * 2010-11-30 2012-06-07 Pradeep Vasant Joshi Composition utilisable dans la construction de bâtiments

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000031174A1 (fr) * 1998-11-23 2000-06-02 W.R. Grace & Co.-Conn. Ouvrabilite et temps d'emploi ameliores dans un mortier de maçonnerie et procede de fabrication correspondant
RU2303581C2 (ru) * 2005-07-20 2007-07-27 Закрытое акционерное общество "Союзтеплострой" Способ получения кладочного раствора для футеровки тепловых агрегатов, преимущественно, в цветной металлургии
CN101337784A (zh) * 2008-08-14 2009-01-07 武汉理工大学 一种建筑砂浆及其制备方法
WO2012073258A2 (fr) * 2010-11-30 2012-06-07 Pradeep Vasant Joshi Composition utilisable dans la construction de bâtiments
CN102276200A (zh) * 2011-05-26 2011-12-14 太原理工大学 废弃纺织纤维砌筑砂浆的制作方法

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104478350A (zh) * 2014-11-19 2015-04-01 海南大学 水产增养殖和海洋生态工程用防海水侵蚀水泥的制备方法
CN107216093A (zh) * 2017-06-20 2017-09-29 武汉理工大学 一种界面增强轻质混凝土及其制备方法
CN109021688A (zh) * 2018-07-27 2018-12-18 郑州汉东科技有限公司 一种环保水性印刷油墨及其制备方法
CN108975753A (zh) * 2018-08-23 2018-12-11 江苏申御特种建材有限公司 一种改性氧化钙类水泥混凝土膨胀剂及其制备方法
CN108975753B (zh) * 2018-08-23 2021-04-09 江苏申御特种建材有限公司 一种改性氧化钙类水泥混凝土膨胀剂及其制备方法
WO2020183429A1 (fr) * 2019-03-14 2020-09-17 Green Build Products India Pvt.Ltd. Composition de mortier et procédé pour sa préparation
CN112830707A (zh) * 2019-11-25 2021-05-25 泰州普利策新材料科技有限公司 一种与eps配合使用的改性母液及制备方法
CN113150661A (zh) * 2021-03-26 2021-07-23 湛江宝钢新型建材科技有限公司 一种铁水脱硫渣基水性底面合一防腐涂料及其制备方法

Similar Documents

Publication Publication Date Title
WO2014083579A1 (fr) Composition pour des mortiers de maçonnerie
CN110255996B (zh) 一种粉煤灰地聚物混凝土及其制备方法
WO2012073258A2 (fr) Composition utilisable dans la construction de bâtiments
Dove et al. Seaweed biopolymers as additives for unfired clay bricks
KR102194680B1 (ko) 수축 저감 효과가 뛰어난 조강 시멘트 콘크리트 조성물 및 이를 이용한 도로포장 유지보수공법
CN105948653A (zh) 一种再生湿拌砂浆及其制备方法
CN100546933C (zh) 钢渣保温抹面砂浆
CN106242327B (zh) 一种再生微粉水泥混合材及其制备方法
AU2010100046A4 (en) A composition suitable for use in building construction
CN101265069A (zh) 一种高强度耐水粉刷石膏及其生产方法
CN104529331A (zh) 防水型高分子益胶泥
KR101617067B1 (ko) 혹한기용 외단열 몰탈 및 이를 이용한 외단열 시스템 시공 방법
CN104973832B (zh) 一种抗裂砂浆及其制备方法
TW200930683A (en) Concrete having high workability through control of fine-to-coarse particulates ratio
CN103193425A (zh) 矿渣集料制备的高强泵送抗裂混凝土及其生产方法
CN113652239B (zh) 一种热带沙漠土专用固化剂及其使用方法
CN108358547A (zh) 一种硅烷偶联剂改性辉绿岩透水混凝土
WO2020183429A1 (fr) Composition de mortier et procédé pour sa préparation
KR101600840B1 (ko) 버텀애쉬를 골재로 활용한 콤팩션 그라우팅(Compaction Grouting) 공법용 속경형 모르타르 조성물
WO2009007994A2 (fr) Composition de matières pour la production de matériau composite à base de résine prépolymérisée et de cendres volantes
CN112930329A (zh) 具低收缩率的碱活化干混修补砂浆
KR101811805B1 (ko) 초속경 강회 및 이를 포함하는 초속경 강회 몰탈
KR20180083756A (ko) 콘크리트 강도 증진용 결합제 및 이를 포함하는 폴리머 시멘트 복합체 조성물
CN110550875A (zh) 一种石灰-偏高岭土改性土及其应用
JP6508789B2 (ja) ポリマーセメントモルタル、及びポリマーセメントモルタルを用いた工法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 13859462

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 13859462

Country of ref document: EP

Kind code of ref document: A1