WO2019216851A2 - Mortier précoulé léger à base de ciment avec agrégat de perlite expansée - Google Patents

Mortier précoulé léger à base de ciment avec agrégat de perlite expansée Download PDF

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Publication number
WO2019216851A2
WO2019216851A2 PCT/TR2019/050037 TR2019050037W WO2019216851A2 WO 2019216851 A2 WO2019216851 A2 WO 2019216851A2 TR 2019050037 W TR2019050037 W TR 2019050037W WO 2019216851 A2 WO2019216851 A2 WO 2019216851A2
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WO
WIPO (PCT)
Prior art keywords
precast
precast mortar
mortar
weight
perlite
Prior art date
Application number
PCT/TR2019/050037
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English (en)
Other versions
WO2019216851A3 (fr
Inventor
Suat Demir
Original Assignee
Anka Vizyon Sinema Yapi Anonim Sirketi
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 Anka Vizyon Sinema Yapi Anonim Sirketi filed Critical Anka Vizyon Sinema Yapi Anonim Sirketi
Publication of WO2019216851A2 publication Critical patent/WO2019216851A2/fr
Publication of WO2019216851A3 publication Critical patent/WO2019216851A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to cement-based light precast mortar formulation with higher water absorption, cracking, stretch, pressure, rotation and impact resistances without any need for iron or steel reinforcement in the concrete, when compared to normal concrete thanks to the alkali-resistant glass fiber, expanded perlite aggregate materials, filling materials, and chemical polymers added into it with short setting time, resistant against atmospheric conditions, exhibiting high resistance and performance with respect to heat, sound, water and fire insulation, which can breath and exhibit structural features that are appropriate for the interior and/or exterior space applications in the construction sector, and which can be filled in the pre-prepared various moulds by ready or special air injection machines according to the form to be produced and the production method of such cement based light precast mortar; and describes the formulation of the precast mortar containing brick dust, expanded perlite, high alkali resistant trimmed glass fiber and vinyl acetate-VeoVa-acrylate (polyvinyl alcohol protected polymer ) and the production method of this formulation developed.
  • Fiber reinforced concretes which were defined as precast exterior fa9ade and which were used in the building applications in the world since l970s were started to be used in Turkey since l980s.
  • the hydraulic binding product containing cement, aggregate and water is called concrete and the concrete obtained by addition of natural and artificial materials with irregular fiber structure, to the concrete prepared is called fiber reinforced concrete.
  • the precast building elements obtained by addition of this concrete derivative increase the deadweight of the building they are applied due to the heavy unit weight of the aggregate materials in the composition (1900-2400 kg/m ) and cause the formation of significant thermal bridges on the application surfaces.
  • the use of expanded perlite aggregate materials is started for obtaining exterior fa9ade precast elements with low unit weight.
  • the light weight of the product is directly related to the low unit weight value of the mortar prepared for the product.
  • the materials with high porosity and very low unit weight obtained by the expansion of the natural perlite materials subjected to expansion at high temperature values (850°C and above) are very important materials for obtaining light precast mortar combinations.
  • the expanded perlite aggregate materials are classified at different grain sizes, they play the role of pore former in the matrix structure of the mortar and also as an inorganic light filling element.
  • the high porosity of these materials enables the production of the precast products with high heat, sound, temperature resistance and high breathability performance.
  • the forms of the mortar combinations with expanded perlite aggregate component, that are created by chemical additives with appropriate properties easily provide for many of the performance criteria that are required in the application areas of the buildings.
  • the invention with the title“thermal and sound insulation plaster obtained by mixing expanded perlite and the natural pumice material and screed aggregate” no TR200802140, describes thermal and sound insulation plaster prepared in order to plaster the interior and exterior facades of the buildings, which contains in its structure, equal amounts of screed aggregate obtained by mixing expanded perlite and pumice and plaster obtained by mixing the cement and water.
  • the inventor experienced problems in the adhesion of the mortar and the bonding texture properties of the expanded perlite aggregate cement-based light precast mortars in the state of the art.
  • the inventor found in the studies carried out with the materials with high water resistance, that the materials with high water repelling features influence the water insulation positively and influence the functionality of the mortar negatively.
  • the purpose of the invention is to obtain cement-based light precast mortar formulation with higher water absorption, cracking, stretch, pressure, rotation and impact resistances without any need for iron or steel reinforcement in the concrete, when compared to normal concrete thanks to the alkali-resistant glass fiber, expanded perlite aggregate materials, filling materials, and chemical polymers added into it with short setting time, resistant against atmospheric conditions, exhibiting high resistance and performance with respect to heat, sound, water and fire insulation, which can breath and exhibit structural features that are appropriate for the interior and/or exterior space applications in the construction sector, and which can be filled in the pre-prepared various moulds by ready or special air injection machines according to the form to be produced.
  • Another purpose of the invention is to develop precast mortar with extended application time and at the same time, to decrease the water volume used in the mixtures and increase the final resistance values of the product. Also, the purpose is to increase the functioning features of the mortar and to develop a mortar with high water resistance properties.
  • the product in the present invention which can easily be used in the production of the panel, plate and/or sheet products to be applied as precast products with different geometric designs specifically on the exterior facades of the buildings in the construction sector, eliminates the disadvantages mentioned above and enables building applications with high energy efficiency.
  • the invention provides significant saving with respect to the labor, time, material, construction techniques, energy consumption.
  • the formulation of the precast mortar of the present invention with structural properties in compliance with the interior and/exterior space applications contains brick dust, expanded perlite, high alkali resistant trimmed glass fiber and vinyl acetate- VeoVa-acrylate (polyvinyl alcohol protected polymer).
  • the brick dust used in the formulations of the developed precast mortar is composed of aggregates classified in specific dimensions which are acquired by breaking and filtering the brick wastes that are well fired. There are foreign materials within the structure of the brick dust, such as coal dusts, soil and stone components. Another significant point of the invention is the inclusion of the brick dust in two different particle sizes such as coarse brick dust and fine brick dust, in the formulation. Coarse brick dust is used within the dimension range of 1- 2mm, fine brick dust is used within the dimension range of 500 micron- lmm.
  • the resistance of the light precast mortar to the weather conditions and flexibility is provided in the formulations developed by two different brick dust sizes thanks to the characteristic structure and the particle sizes of the materials.
  • Expanded perlite used in the precast mortar formulations developed is classified at the dimension of 500 microns-3mm and is subjected to expansion under high temperatures. Following the expansion procedure, the density of the expanded perlite material appropriate for the production of the light precast mortar varies between 60-l80kg/m .
  • the lightness of the precast mortar to be obtained due to the low unit volume mass values of this material is fundamental for providing the heat, sound and fire insulation properties and also is fundamental for providing the breathability (formation of vapor diffusion capability) of the product.
  • Trimmed glass fiber with high alkali resistance, with high resistance against chemicals and high temperatures is used in order to provide the compliance of the cement-based light precast mortar with expanded perlite aggregate with the design, the properties of lightness and easy formability, to have the mortar provide pressure, bending, impact and tensile resistance increasing effects, to create helical and lattice bond structure, to provide crack control and to exhibit a long life performance.
  • This glass fiber reinforcement does not react with the alkali elements in the concrete by time, thus enables the usage in many different applications such as the concrete panel products, separation panels, exterior fa ade elements, cable boxes, drainage channels and the concrete derivative works of fine arts.
  • the powder additive used in the formulations developed in the present invention is vinyl acetate-veova-acrylate (polyvinyl alcohol protected powder polymer).
  • the most important characteristic of the polymer is that it can be used at low film formation temperatures and in modified mixtures containing hydraulic binder. It is influential in increasing the application time of the mortar and it decreases the water volume used in the mixtures, accordingly raises the final resistance values of the product.
  • the problems encountered in the state of the art were solved by increasing the functionality feature of the mortar and raising the water resistance. Also, it enables water insulation features thanks to the high water repelling qualities provided to the mortar.
  • the precast mortar developed contains at least one filling material.
  • the mentioned filling material can be selected from the filling materials used in the construction sector in the state of the art.
  • fine raw perlite and/or micronized dolomite are used as the filling material for the precast mortar of the present invention.
  • the natural-origin fine raw perlite aggregate obtained by breaking and grinding the natural perlite stone classified within the dimension range of 125 microns to 500 microns is used in the precast mortars.
  • the natural perlite rock usually exists in nature as granular perlite, pumice perlite, devitrified perlite, fiber perlite and penocrystalline perlite, based on its petrographic structure.
  • the perlite used within the scope of the present invention is preferably obtained from“fiber perlite” among these natural formations.
  • Fine raw perlite is a significant component for the present invention and is used as a filling material which increases the resistance in the matrix structure of the cement-based light precast mortar. Fine raw perlite also reduces the water absorption capability of the light precast mortar, thanks to its low water absorption.
  • micronized dolomite for which the largest grain size is classified as 5 microns.
  • Micronized dolomite is obtained by breaking, sifting and grinding the natural mineral rock containing calcium and magnesium carbonate in its composition.
  • Micronized dolomite is used as the filling material in the light precast mortar mixture within the scope of the present invention and it is a material which improves the resistance of the hardened mortar against the high temperatures, thanks to the magnesium content within its composition. It is an additive component which balances the resistance of the mortar following the hardening and the chemical correspondence of the matrix structure.
  • Another characteristic of the light precast mortar of the present invention is that it contains at least one bonding material in its structure.
  • the mentioned bonding material can be selected from the bonding materials available in the construction sector in the state of the art.
  • Portland cement is used as the bonding material for the precast mortar of the present invention.
  • Another characteristic of the light precast mortar of the present invention is that it contains at least one pH balancing agent in its structure.
  • the mentioned pH balancing agent can be selected from the pH agents available in the construction sector in the state of the art.
  • slaked powder lime is used as the pH balancing agent for the precast mortar of the present invention.
  • Ideal slaked powder lime for the production of light precast mortar should at least have 84% Ca(OH) 2 content with 70 microns to 250 microns grain size range, fineness maximum between the range of 3-10%, ignition loss not exceeding maximum 8% and with S0 3 content of maximum 1% in its structure.
  • CL 90 slaked powder lime also serves as pH balancer in the mortar obtained within the scope of the present invention.
  • Another characteristic of the light precast mortar of the present invention is that it contains at least one plasticizer material in its structure.
  • the mentioned plasticizer material can be selected from the plasticizer materials available in the construction sector in the state of the art.
  • melamine material is used as the plasticizer material for the precast mortar of the present invention.
  • Highly plasticizer material to reduce the water is added to the mortar during mixing, on condition not to exceed 1,5% of the cement mass, in order to develop the characteristics of the cement-based light precast mortar with expanded perlite aggregate in its fresh and/or hardened state, to enable the production of high performance precast elements.
  • Melamine in its powder form which reduces the mixture water and provides a high level of fluidity, and which can even be used at low temperatures, is very appropriate plasticizer to be used in cement-based materials. It has a chemical effect which provides considerable reduction of water volume without changing the consistency in the light precast mortar composition or increases the precipitation/diffusion without changing the water volume or provides both.
  • Another characteristic of the light precast mortar of the present invention is that it contains expanded powder perlite in its structure.
  • the light precast mortar of the present invention contains at least one water repellent chemical material in its structure.
  • the mentioned water repellent chemical material can be selected from the water repellent chemical materials available in the construction sector in the state of the art.
  • silane and/or silicone materials are used as the water repellent chemical material for the precast mortar of the present invention.
  • Water repellent chemical material can be used in its powder and/or liquid form that are compatible with the cement based mixtures in order to provide water repelling features for the light precast mortar following the hardening.
  • Another characteristic of the light precast mortar of the present invention is that it contains brick dust, expanded perlite, high alkali resistant trimmed glass fiber, vinyl acetate-veova- acrylate (polyvinyl alcohol protected polymer), Portland cement, micronized dolomite, expanded powder perlite, slaked powder lime, plasticizer material, water repellent chemical material.
  • the components in the new formulation developed for the light precast of the present invention are as 17-29% brick dust by weight, 7-15% expanded perlite by weight, 0.5-3% high alkali resistant trimmed glass fiber by weight, 0.2-1% vinyl acetate-veova-acrylate polymer by weight, 28-40% Portland cement by weight, 4-10% micronized dolomite by weight, 4-10% expanded powder perlite by weight, 1.5-5% slaked powder lime by weight, 0.2-1.5% plasticizer material by weight, 02-14% water repellent chemical material by weight.
  • Another characteristic of the invention is that the coarse brick dust is between 9% - 15% and the fine brick dust is between 8% - 14% by weight in the formulation developed.
  • the light precast mortar of the present invention contains at least one color powder paint and/or color pigment in its structure.
  • the paints and/or color pigments in the state of the art can be used in the formulations of the present invention. They are optional for coloring the mortar.
  • the materials and their weights by percentage for the cement-based light precast mortar with expanded perlite aggregate prepared are given in Table 1 in a sampling of the present invention.
  • the process steps of the production method of the light precast mortar of the present invention are composed of; mixing at least two materials to be selected from the coarse brick dust, fine brick dust, fine raw perlite, micronized dolomite and slaked powder lime materials in a mixing tank in order to form the first mixture; mixing at least two materials to be selected from Portland cement, high alkali resistant trimmed glass fiber materials in another mixing tank in order to form the second mixture; mixing at least two materials to be selected from plasticizer material, vinyl acetate veove- acrylate polymer, water repellent chemical material and color powder paint materials in another mixing tank in order to form the third mixture; mixing of three mixtures created in the mixing tank in order to form the final mixture; weighing the expanded perlite and/or expanded powder perlite materials and addition to the final mixture; feeding water into the mixture, preferably; filling the mixture into the moulds.
  • the function of this mixture can be named as “binder and fiber mixture”.
  • the plasticizer material, powder polymer additive, water repellent chemical material and color powder paint and/or color pigment adjusted as based on their percentages within the mixture are added to the third mixing tank, and the mixture is mixed at least for 3 minutes in order to obtain a homogenous mixture and the homogeneity of the materials is provided.
  • This mixture function can be named as“chemical mixture”.
  • The“raw material mixture”,“binder and fiber mixture” and“chemical mixture”s obtained are taken into a different mixer tank and are mixed for 2 minutes at low speed and the homogeneity of these three materials is provided. Following this, expanded perlite and expanded powder perlite are weighed and added into this mixer at the percentages to be used in the total mixture.
  • This light precast mortar obtained is filled in the moulds produced of steel, polyester, wood and/or silicone for which the geometry, dimension and shape is designed and homogenous settlement of the mortar in the mould is provided by a vibration unit. Attention is paid so that open surfaces of the moulds filled with mortar are completely smooth following the filling process. These moulds, if required, are kept in a drying oven for at least 8 hours at a temperature of minimum 60-70°C after the filling process and the mortar is cured. Cured light precast mortar is removed from the moulds and the precast product is obtained. Completely hardened precast products go through the final quality controls, they are packed and final product form is achieved.
  • the production of cement-based light precast mortar with expanded perlite aggregate which can be used in the interior and/or exterior fa ade applications can be provided by taking the use ranges defined within the frame of the mixture components of the mortar and material use percentages.
  • Precast products in the form of plates can be obtained with the cement-based light precast mortar with expanded perlite aggregate of the present invention, which can be applied up to 20 mm.
  • the unit weight value of the precast products to be produced with the light precast mortar combinations of the present invention, for the product thickness of 10 mm as a hardened mortar product, can vary between 6-11 kg/m2 based on the combination of the mixture applied.

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

Abstract

La présente invention concerne une formulation de mortier précoulé léger à base de ciment présentant une absorption d'eau, des résistances au craquèlement, à l'étirement, à la pression, à la rotation et au choc plus élevées sans nécessiter de renfort de fer ou d'acier dans le béton, par rapport au béton normal, grâce à une fibre de verre résistant aux alcalis, des matériaux d'agrégat de perlite expansée, des matériaux de charge et des polymères chimiques qui y sont ajoutés avec un temps de durcissement court, résistant aux conditions atmosphériques, présentant une résistance et une performance élevées par rapport à la chaleur, au son, à l'eau et à l'isolation contre le feu, qui peut respirer et présente des caractéristiques structurelles qui conviennent à des applications d'espace intérieur et/ou extérieur dans le secteur du bâtiment, et qui peut être introduit dans différents moules pré-préparés par des machines d'injection d'air prêtes ou spéciales selon la forme à produire et le procédé de production d'un tel mortier précoulé léger à base de ciment; et l'invention concerne la formulation du mortier précoulé contenant de la poussière de brique, de la perlite expansée, de la fibre de verre coupée résistante aux alcalis forts et de l'acétate de vinyle-VeoVa-acrylate (polymère protégé par l'alcool polyvinylique) et le procédé de production de cette formulation développée.
PCT/TR2019/050037 2018-01-17 2019-01-17 Mortier précoulé léger à base de ciment avec agrégat de perlite expansée WO2019216851A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2018/00610 2018-01-17
TR2018/00610A TR201800610A2 (tr) 2018-01-17 2018-01-17 Genleşmi̇ş perli̇t agregali çi̇mento esasli hafi̇f prekast harci

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WO2019216851A2 true WO2019216851A2 (fr) 2019-11-14
WO2019216851A3 WO2019216851A3 (fr) 2020-01-09

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111747728A (zh) * 2020-05-13 2020-10-09 九江市璀鑫新材料有限公司 一种高强度耐碱砖制备方法
EP3909937A1 (fr) * 2020-05-15 2021-11-17 TPI Polene Public Company Limited Matériau de ciment léger renforcé par des fibres
CN114230285A (zh) * 2021-12-29 2022-03-25 山东汇富建设集团有限公司 一种装配式绿色建筑保温墙体结构及其装配方法
CN114560665A (zh) * 2022-04-07 2022-05-31 武汉质高环保科技有限公司 一种用于建筑内墙的相变保温饰面砂浆及其制备方法
CN115180894A (zh) * 2022-06-27 2022-10-14 中建八局第三建设有限公司 一种用于古建筑墙体修复的青砖及其制备方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113149547B (zh) * 2021-03-25 2023-07-14 沈阳理工大学 一种碱激发再生粘土砖粉胶凝材料及其制备方法和应用

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US5180795A (en) * 1990-08-02 1993-01-19 Borden, Inc. Retarders for hardening phenolic resins
JP2881077B2 (ja) * 1992-09-19 1999-04-12 菊水化学工業株式会社 無公害性耐火被覆組成物
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111747728A (zh) * 2020-05-13 2020-10-09 九江市璀鑫新材料有限公司 一种高强度耐碱砖制备方法
EP3909937A1 (fr) * 2020-05-15 2021-11-17 TPI Polene Public Company Limited Matériau de ciment léger renforcé par des fibres
CN114230285A (zh) * 2021-12-29 2022-03-25 山东汇富建设集团有限公司 一种装配式绿色建筑保温墙体结构及其装配方法
CN114230285B (zh) * 2021-12-29 2023-07-04 山东汇富建设集团有限公司 一种装配式绿色建筑保温墙体结构及其装配方法
CN114560665A (zh) * 2022-04-07 2022-05-31 武汉质高环保科技有限公司 一种用于建筑内墙的相变保温饰面砂浆及其制备方法
CN114560665B (zh) * 2022-04-07 2023-08-11 武汉质高环保科技有限公司 一种用于建筑内墙的相变保温饰面砂浆及其制备方法
CN115180894A (zh) * 2022-06-27 2022-10-14 中建八局第三建设有限公司 一种用于古建筑墙体修复的青砖及其制备方法

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WO2019216851A3 (fr) 2020-01-09

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