WO2019240705A2

WO2019240705A2 - Natural, light aggregate precast composite mortar with insulation properties, inorganic binding system

Info

Publication number: WO2019240705A2
Application number: PCT/TR2019/050038
Authority: WO
Inventors: Suat Demir
Original assignee: Anka Vizyon Sinema Yapi Anonim Sirketi
Priority date: 2018-01-31
Filing date: 2019-01-17
Publication date: 2019-12-19
Also published as: WO2019240705A3

Abstract

The present invention relates to precast composite mortar with inorganic binding system 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, natural and/or artificial light aggregate materials, inorganic filling materials and special chemicals 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 describes the formulation containing fine granule volcanic aggregate, coarse granule volcanic aggregate, calcined diatomite additive, modified anhydride, alkali resistant glass fiber and the production method developed for this formulation.

Description

NATURAL, LIGHT AGGREGATE PRECAST COMPOSITE MORTAR WITH INSULATION PROPERTIES, INORGANIC BINDING SYSTEM

Technical Field

The present invention relates to precast composite mortar with inorganic binding system 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, natural and/or artificial light aggregate materials, inorganic filling materials and special chemicals 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.

The present invention does not contain any toxic and allergenic materials which threaten or are harmful for human health. Moreover, the mortar composition does not contain any radioactive component which has values higher than those radioactivity values which are accepted to be within the normal limits as accepted by the international health institutions. GG does not contain any inflammable, flammable, smoke generating, explosive and combustive organic materials.

Prior Art

In the state of the art, there are concrete products with glass fiber reinforcement and concrete element products with specially designed geometric forms used in the structural fa9ade design and production in the construction industry. 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. Today, 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. Together with this, the difficulties in the connection and installation functions are inevitable within the context of weight measurement. The precast products which are deformed rapidly specifically under the exterior atmospheric conditions are frequently used in the sectoral applications due to their structural composition. Although the exterior fa9ade precast applications have positive effects on the external visuality and the architectural arrangements of the buildings, some technical characteristic values required in the materials, which shall be used in the exterior fa ade applications under current conditions, are not satisfied sufficiently, when the material structures are technically examined. Within this context, it is very important for the precast mortar to have a low weight, that it loads reasonable weight on the building at considerable scales, is not affected by the UV rays of the sun, it has a composition which does not decompose under atmospheric conditions, acid, base and salty mediums, contributes high value added to the thermal and acoustic comfort conditions in the area it is applied and has breathing properties.

In order to eliminate these problems, the new generation composite mortar precast elements are started to be used by utilization of porous light aggregate/granules of different origin in combination and by providing the harmony in the matrix structures created, for obtaining exterior fa9ade precast elements with low unit weight. The high porosity of these aggregate/granule material derivatives enables the production of precast products with high performance in heat, sound, high temperature resistance and breathability. Moreover, in the state of the art, the appropriate chemical additives and the matrix structures in the composite forms of the mortar combinations with this material derivative component easily provide for many performance criteria needed in the application places of the buildings. In addition, the building elements produced with these material derivatives have very high values with respect to water, fire resistance and hygienic properties as well as the heat and sound insulation performances. Precast products provide ease of application in the high-rise building projects as well as increasing the building’s resistance against earthquakes since it considerably decreases the dead weight values and also provides the thermal and acoustic comfort conditions required for the high-rise applications. Within this context, the new generation precast composite mortar combinations with inorganic binders can be obtained by using porous aggregate with natural components for obtaining innovative light precast products and supporting such aggregates with chemical mixtures under appropriate conditions. This fact also provides the development of new derivative panel, plate and/or sheet products for the construction industry. With these mortar combinations, it is possible to produce any surface textures and different forms by various moulds such as wood, polyester, steel, rubber-silicone. Moreover, precast fa ade panels in the form of a shell, which are removed out of the moulds with a thickness between 1.0 - 1.8 cm, are made very rigid by the support of carrier steel box profiles and the system carrier carcass detail is connected to the precast shell with flexible anchorage elements by selecting appropriate sections according to the dimensions of the precast elements.

The inventor had problems in selection of the binder material appropriate for these porous structures in the studies carried out with the precast mortars obtained by the use of porous light aggregate/granules of different origin in combination in order to obtain exterior precast elements with low unit weight in the state of the art. While rapid settlement of the binders is desired for the precast products to be obtained with the materials used for the binding systems in the precast composite mortar, it is also required that it should not lose resistance. In order to overcome this problem in the state of the art, the studies are started to improve the technical properties of the precast mortar, to develop the formulation and improve the production method.

Description of the Invention

The purpose of the invention is to obtain precast composite mortar with inorganic binding system 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, natural and/or artificial light aggregate materials, inorganic filling materials and special chemicals 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 provide rapid settlement of the binders for the production speed of the precast products to be obtained with the new precast mortar formulation developed and to prevent the loss of resistance. Moreover, the matrix structure is provided to have a tough characteristic in the hardened mortar. The precast elements produced with natural light aggregate precast composite mortar with inorganic binding system provide lighter solutions in the traditional wall systems, which are resistant against earthquake and can be applied rapidly. The precast products produced with precast composite mortar with inorganic binding system can be applied to the building by curtain wall method from outside the reinforced concrete and the interior spaces are not narrowed. This shall be an important advantage in the application. Also, the precast products can be produced in any size as based on the project details and applicability of the installation.

The precast composite mortar with inorganic binding system defined in the present invention can easily be used in the production or precast products with different geometric designs such as panel, plate and/or sheet products, specifically on the exterior facades of the buildings in the construction sector. The product of the present invention shall also enable the production of precast products with technical advantages which can eliminate the disadvantages mentioned above and enable building applications with high energy efficiency. The invention provides significant saving with respect to the labor, time, material, construction techniques, energy consumption.

Detailed Description of the Invention

The developed formulation of the precast composite mortar with inorganic binding system of the present invention, which exhibits 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, contains fine granule volcanic aggregate, coarse granule volcanic aggregate, calcined diatomite additive, modified anhydride, alkali resistant glass fiber.

Fine granule volcanic aggregate used in the formulation of the precast mortar developed is a naturally obtained material with particle size classified between the range of 125 microns to 500 microns, containing minimum 55% Si0₂ maximum 4% Fe₂0₃, maximum 10% total alkali (Na₂0+K₂0), minimum 10% Al₂0₃in its chemical composition, with hollow structure, having a structural degradation temperature of minimum 700°C, and bulk dry unit volume mass value less than 950kg/m . This material does not represent the natural materials existing in the nature in a natural porous state, but does not meet the technical characteristics such as the chemical composition limit values, structural degradation temperature degrees and dry bulk unit volume mass values. This material, thanks to its chemical features and porous structure, is one of the basic elements that provides the resistance of the precast composite mortar to be obtained against the external weather conditions, specifically by allowing the required expansion of the matrix structure of the mortar in cases of freezing -defrosting to occur at cold climate conditions and also it provides the insulation properties. Fine granule volcanic aggregate dimension for the production of precast composite mortar with inorganic binding system can also be used as 125 - 500 microns (0.125 - 0.500 mm), 125 - 250 microns and 250 - 500 microns. In this dimension distribution, a single material can also be prepared by mixing fine granule volcanic aggregate as size 125 - 250 microns for 35% and size 250 - 500 microns for 65%.

Coarse granule volcanic aggregate used in the formulation of the precast mortar developed is a naturally obtained material with particle size classified between the range of 500 microns to 4 mm, containing minimum 55% Si0₂ maximum 4% Fe₂0₃, maximum 10% total alkali (Na₂0+K₂0), minimum 10% Al₂0₃in its chemical composition, with hollow structure, having a structural degradation temperature of minimum 700°C, and bulk dry unit volume mass value less than 650kg/m . This material does not represent the natural materials existing in the nature in a natural porous state, but does not meet the technical characteristics such as the chemical composition limit values, structural degradation temperature degrees and dry bulk unit volume mass values. This material, thanks to its low volume mass value, decreases the density of the precast composite mortar to be obtained, makes it light and provides a flexible matrix structure and heat and sound insulation properties for the mortar. Coarse granule volcanic aggregate dimension for the production of precast composite mortar with inorganic binding system can also be used as 500 microns - 4 mm (0.5 - 4.0 mm), 500 microns - 2 mm and 2-4 mm. In this dimension distribution, a single material can also be prepared by mixing coarse granule volcanic aggregate as size 500 microns - 2 mm for 43% and size 2 - 4 mm for 57%.

Calcined diatomite additive used in the formulation of the precast mortar developed is obtained by calcination of the natural diatomite rock with porous structure in a furnace at 800°C or above, containing minimum 80% Si0₂ maximum 2.2% Fe₂0₃, maximum 1.5% total alkali (Na₂0+K₂0), maximum 5% Al₂0₃ in its chemical composition, which is classified below 1 mm of particle size. During this calcination process, the organic maters within diatomite structure are burned and removed and the pores of the diatomite shell are opened. The particles within the structure of the material shrink, are hardened and the particles come together are combined. Diatomite; is a precipitate which is formed of the fossilized shells of the single cell microscopic algae containing silica, called diatom. The cell walls of the diatoms (shells) are composed of amorphous silica (Si0₂ nH₂0). However, this opal (amorphous silica) exists together with the silicates of Al, Fe, Ca, Mg, Na and K elements at various rations. The diatomite used within the frame of the present invention represents a material form which is obtained by calcination, roasting of the natural diatomite rock through a thermal process and its structural properties are changed physically and accordingly, it deviates from its natural state. It is a material different than the diatomite material that exists in nature. Due to the structural properties and closed porosity of the calcined diatomite, it is one of the basic elements that provide high resistance against fire for the precast composite mortar, as well as low values of heat, sound and electrical conductivity. Moreover, vapor diffusion property is also provided to the matrix structure of the mortar, thanks to the calcined diatomite additive. Low unit weight value is another advantage that provides low density for the precast composite mortar. Together with this, the matrix structure of the hardened mortar is provided to be more flexible and more sensitive and stable to the ambient conditions, due to its porosity.

Another material used in the precast mortar formulations developed is modified anhydride. Modified anhydrite material is obtained as follows: Natural magnesite rock is first reduced to the size of 500 microns by breaking, grinding and dimensioning processes and then is blended with grinded natural gypsum. This mixture is calcined over a temperature of 650°C, and a new derivative binding material with high magnesia content and binding properties, which is compatible with white Portland cement, and hardens rapidly, is obtained. These calcination processes can also be carried out separately for each material and then they can be combined and a mixture can be formed. For the production speed of the precast products by the use of precast composite mortar, it is required that the binders settle quickly and not lose resistance during this process. Modified anhydrite is an important element that provides this characteristic of the mixture within the scope of the present invention. Moreover, it also contributes to the toughness of the matrix structure of the hardened mortar.

Another material used in the precast mortar formulations developed is alkali resistant glass fiber with zirconium content (Zr0₂), which provides compliance with the design, lightness and easy formability for the precast composite mortar with inorganic binding system and increases the mortar’s pressure, bending, impact and tensile resistance, controls cracks and exhibits a long life performance. Alkali resistant glass fiber used in the present invention is a type of glass fiber containing zirconium. Glass fiber is generally fine fiber materials that are produced by the use of glass raw materials which are similar to those used in the production of flat glass. Different types of glass fiber can be produced with the addition of different components. Today, 3 different types of glass fiber are produced. These are: isolation-type glass fiber (glass wool), textile-type glass fiber and optical glass fiber. However, more derivative glass fiber reinforcement elements are seen in the production of fiber added materials in the literature with respect to the relevant sector. For example, these are generally named as follows with the sectoral use: A-glass: It is the first type of glass fiber produced. It needed improvement since it was not resistant against alkali. E-glass: Alumino-borasilicate. It is the glass fiber that is resistant against alkali and has electrical properties. S-glass: It is produced due to the need for a higher tensile strength than E-glass. (S: high strength). C-glass: It is produced as resistant against chemicals (specifically, acids). (In North America, this is known as T-glass). The type of glass fiber used in the present invention is glass fiber with zirconium content, highly resistant against alkali mediums and it differs from the derivatives of glass fiber defined above. This glass fiber reinforcement is used in order to provide strength against high alkali volumes in the concrete by time. The most important characteristic of alkali resistant glass fiber is the quantity of the zirconium (Zr0₂) which provides alkali and acid resistance. Glass fiber reinforcement provides additional strength, flexibility and lightness to the concrete produced of precast composite mortar. Glass fiber reinforcement in the present invention does not react with the alkali components and it enables the usage in the concrete panel products, separation panels, exterior fa ade elements, cable boxes, drainage channels and the concrete derivative works of fine arts produced of precast composite mortar.

Another characteristic of the precast mortar formulations developed is the use of volcanic ash as the resistance-increasing additive material. This material is classified within the dimension range of 40 microns to 750 microns, and it contains minimum 40% Si0₂ maximum 8% Fe₂0₃, maximum 9% total alkali (Na₂0+K₂0), minimum 15% Al₂0₃ in its chemical composition, with natural origin, having a structural degradation temperature of minimum 780°C. This material can have acidic/basic features. If basic, it should not form rust and should not oxidize as a result of the chemical reaction due to the iron content within its structure. Volcanic ash increases the toughness of the bonding to be formed in the mortar matrix structure and enables the formation of a mortar structure that is resistant against the ambient conditions and has a long life. The dimension of the volcanic ash for the production of precast composite mortar with inorganic binding system can be arranged as 40 - 750 microns (0.04 - 0.75 mm), 40 - 250 microns ad 250 - 750 microns. The volcanic ash between the range of 40 - 250 microns as 58% by weight, 250 - 750 microns as 42% by weight can be mixed in order to be used in the precast mortar production.

Another characteristic of the precast mortar formulations developed is the use of micronized limestone as the filling material. Micronized limestone, which is a natural-origin aggregate with the largest particle size classified as 100 microns, containing at least 90% CaC0₃ (calcium carbonate) as the chemical component within its structure can be obtained from a sedimentary rock in nature composed of carbonate salt or can be grinded from the glassy shiny, colorless transparent calcite mineral formations in various crystalized forms such as rhombohedron and scalenohedron. Micronized limestone is used as the filing material in the precast composite mortar mixture of the present invention. It is an additive component balancing the resistance and the chemical harmony of the matrix structure following the hardening of the mortar. It is important that the components such as Si0₂, Al₂0₃ and Fe₂0₃ are at minimum in the chemical composition of the rock and/or mineral from which the micronized limestone is obtained by grinding. Moreover, micronized limestone obtained from the rocks with fine crystals provides higher performance in the composite mortar matrix of the present invention.

Another characteristic of the precast mortar formulations developed is the use of fine sand as the additive for increasing the resistance. Fine sand with the largest particle size of 375 microns, containing at least 92% Si0₂ (silicon dioxide) as the chemical component within its structure, with porosity less than 2% can also be obtained dimensioning following the breaking and grinding of a natural material formation with high ratio of silicon dioxide in its structure. There can be low ratios of aluminum, iron and calcium oxide components in its chemical structure. The total weight of these oxide components should not exceed 105. Due to its high hardness, it is a very important resistance increasing additive material of the precast composite mortar. Moreover, fine sand provides considerable improvement for the precast composite mortar against heat and chemical effects wince it has a high resistance against these. It is required that the particle surfaces of the fine sand to be used in the mortar to be obtained according to the present invention, does not have a dusting behavior and is free of components such as clay etc. and should be in dry material form.

Another characteristic of the precast mortar formulations developed is the use of raw perlite classified as the additive for increasing the resistance. Raw perlite with natural origin, obtained by breaking and grinding the natural perlite rock, of which the largest particle is classified as 250 microns is used in the precast mortars. In general, the perlite materials are known to be used in the construction sector in the production of the building materials in the “expanded perlite” form subjected to high temperature. However, the perlite used in the present invention is a material which is used in its natural form, without being subjected to any expansion process. 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 obtained from“fiber perlite” among these natural formations. Classified raw perlite is a significant component for the present invention and is used for strengthening the binding texture in the inorganic binding system and for increasing the pressure resistance and impact resistance of the hardened mortar. Classified raw perlite also reduces the water absorption capability of the precast composite mortar, thanks to its low water absorption.

Another characteristic of the precast mortar formulations developed is the use of cement as binding material. The cement used in the present invention can be gran and/or white Portland cement.

Another characteristic of the precast mortar formulations developed is the addition of highly water reducing“plasticizer chemical additive” to the mortar during the mixing process, on condition not to exceed 5% of the cement mass in order to develop the properties of the precast composite mortar with inorganic binding system in its fresh and/or hardened state, to enable the production of high performance precast elements. It has a chemical effect which provides considerable reduction of water volume without changing the consistency in the precast composite mortar composition or increases the precipitation/diffusion without changing the water volume or provides both. This additive provides the homogenous distribution of the cement in the mortar, decreases the water need of the mortar and increases the density and water impermeability of the mortar. Fine/coarse aggregates in the mortar provide perfect wetting of the cement, mineral additives. This way, the pressure resistance and the strength of the mortar increases. The plasticizer material materials available in the construction sector in the state of the art can be used as the plasticizer material for the precast mortar of the present invention. Preferably melamine material is used in the present invention.

Another characteristic of the precast mortar formulations developed is the use of polymer additive in powder and/or liquid form compatible with cement-based mixtures in order to provide hydrophobic (water repellant) properties for the precast composite mortar with inorganic binding system, after the application. This polymer additive can be silane and/or silicon based polymer. It is used in order to prevent the capillary movement of the water in hardened mortar and to provide water absorption resistance throughout the material. The diffusion within the water should be easy in the mixture. Another characteristic of the precast mortar formulations developed is that it contains “Coloring Agent” in order to give color to the mortar. The coloring agent used in the present invention is smooth, round, natural or synthetic, inorganic or organic, undissolved, diffused color powder agents. These powder agents diffuse in the mortar mixture and improve the basic properties of the mortar such as opaqueness, thickness, resistance and corrosion resistance, as well as coloring it. The color powder agents used in the present invention can be natural and/or artificial inorganic, organic components or mixtures containing both.

The precast composite mortar with inorganic binding system preferably contains volcanic aggregate of 23%-37% by weight, calcined diatomite additive of 2%-5% by weight, modified anhydrite of 2%-8% by weight, alkali glass fiber 0.75-3.5% by weight, binding material of 32%-42 by weight, volcanic ash of 8%-20% by weight. More preferably, the mortar formulation contains fine granule volcanic aggregate of 8%- 14% by weight, coarse granule volcanic aggregate of l5%-23% by weight.

The materials and their weights by percentage for the precast mortar prepared are given in Table 1 in a sampling of the present invention. Table 1 : The materials in the precast composite mortar with inorganic binding system and their weights by percentage

Content Usable Percentage by Weight

Fine Granule Material 8% - 12%

Coarse Granule Material 15% - 20%

Volcanic Ash 8% - 15%

Micronized Limestone 2% - 5%

Fine Sand 7% - 12%

Classified Raw Perlite 3% - 7%

Calcined Diatomite Additive 2% - 5%

Cement 32% - 40%

Modified Anhydrite 2% - 6% Alkali Resistant Glass Fiber 0.75% - 3.5%

Plasticizer Chemical Additive 0.15% - 1.20%

Polymer Additive 0.35% - 0.85%

Coloring Agent 0.10% - 0.20%

Mixing, weighing, moulding and filling process steps are used as the production method in general for the preparation of the precast composite mortar with inorganic binding system in the present invention. The process steps of the production method of the precast composite mortar with inorganic binding system of the present invention are composed of the following process steps:

• Mixing at least two materials to be selected from volcanic aggregate, volcanic ash, micronized limestone, fine sand, raw perlite, calcined diatomite additive materials, in a mixing tank in order to form the first mixture,

· Mixing at least two materials to be selected from cement, modified anhydrite, alkali resistant glass fiber materials, in another mixing tank in order to form the second mixture,

• Mixing of two mixtures in another mixing tank in order to form the final mixture.

Another characteristic of the production method of the precast composite mortar with inorganic binding system of the present invention is that it includes the process step of preparation of a third mixture containing polymer additive and/or coloring agent in a mixing tank and its addition to the final mixture.

Another characteristic of the production method of the precast composite mortar with inorganic binding system of the present invention is that it includes the process steps of moulding and filling.

Another characteristic of the production method of the precast composite mortar with inorganic binding system of the present invention is that it contains a preliminary humidification step for the first mixture. During the preliminary humidification, a little amount of water is added in order to reduce the surface tensions of the aggregate of the first mixture mixed in the powder form and it is mixed for about 2 minutes. At this stage, the preliminary humidification and also homogenous mixing of the material surfaces are provided. The detailed description of the application of the invention to the industry is given below:

For the production of the precast composite mortar with inorganic binding system in the sample mentioned above, seven different mixture components, fine granule material, coarse granule material, volcanic ash, micronized limestone, fine sand, classified raw perlite and calcined diatomite additive materials in a ready to use form according to the technical properties and dimension ranges described in the specification, are placed in a mixing tank in order to obtain a dry, homogenous mixture and are mixed for at least 5 minutes. Since this aggregate mixture is in dry powder form in the beginning and since some aggregate materials have high water absorption values, first it is required to reduce the surface tensions of the aggregate. At this stage, little amount of water is added into the tank for preliminary humidification of the priorly mixed powder form, and it is mixed for 2 minutes for providing the preliminary humidification of the aggregate and reduction of the surface tension. Following this process, the preliminary humidification and homogenous mixing of the material surfaces are provided. This mixing process is named as“raw material mixture”. Another mixing process is performed by adding cement, modified anhydride and alkali resistant glass fiber material components into another mixing tank and by mixing it for at least 3 minutes in order to obtain a homogenous mixture. It is very important that the fiber reinforcement material is homogenously diffused and does not flocculate. The function of this mixture can be called“binding and reinforcement mixture. The powder polymer additive, and color coloring agent, all in powder form, 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“additive mixture”. Weighed water to be used in the total mixture which shall provide smooth diffusion and operability of the mortar is placed in another mixing tank. Plasticizer chemical additive is added to this water and mixing is continued for 3 minutes at high speed and homogenous dissolution of the chemical additive is provided in the water. This mixing function can be called as“thickening agent”. The raw material, binding and reinforcement mixtures from the mixture stages mentioned above and the additive mixture materials are transferred to a mixing tank which shall be the main mixer afterwards and are mixed for at least 2 minutes. Following this, the mixer continues to mix at low speed and thickening agent is added to it slowly in order to obtain a homogenous mixture. During these mixture processes, it should attentively be observed whether particle alternation and segregation is formed due to the densities of the materials. A mortar medium in which no segregation appears can be named as“final precast mortar”. Following this process, final precast composite mortar is ready for moulding process. This final precast composite mortar obtained is then 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 he mortar is cured. Cured final precast composite 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 precast composite mortar with inorganic binding system 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 given in Table 1.

Precast products in the form of plates can be obtained with the precast composite mortar with inorganic binding system of the present invention, which can be applied up to 18 mm. The unit weight value of the precast products to be produced with the composite mortar combinations of the present invention, for the product thickness of 10 mm as a hardened mortar product, can vary between 9.5-16 kg/m2 based on the combination of the mixture applied.

When it is considered that the products in plate form with the nominal values and plate thicknesses provided in Table 2 are produced with the precast composite mortar with inorganic binding system of the present invention, the technical parameter value ranges given in Table 3 can be achieved.

Table 2. The nominal values and plate thicknesses of the plates that can be produced with the precast composite mortar with inorganic binding system Dimension Ranges

Thickness Length Width Plate Surface Area

(mm) (mm) (mm) (m²)

10, 12.5 and 18 2500 1200 3.0

10, 12.5 and 18 3000 1200 3.6

Table 3. Some technical values of the plates that can be produced with the precast composite mortar with inorganic binding system

Plate Plate Plate Dry Weight Thermal

Thickness Surface Weight Value Range for Conductivity Value

Value Area Value Range Unit m² area of the Plate in Dry

State

(mm) (m²) (kg/plate) (kg/m²) (W/mK)

10 3ΪG 28.5-48.0 9.5-16.0

12.5 3.0 35.6-60.0 11.9-20.0

15 3.0 42.8-72.0 14.3-24.0 0.40-0.90

18 3.0 51.3-91.8 17.1-28.8

10 3.6 34.2-57.6 9.5-16.0

12.5 3.6 42.8-72.0 11.9-20.0

15 3.6 51.3-86.4 14.3-24.0 0.40.90

18 3.6 61.6-103.7 17.1-28.8

Claims

1. The present invention is precast composite mortar with inorganic binding system with structural characteristics appropriate for the interior and/or exterior spaces in the construction sector and it is characterized by; containing fine granule volcanic aggregate, coarse granule volcanic aggregate, calcined diatomite additive, modified anhydrite, alkali resistant glass fiber.

2. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing fine granule volcanic aggregate with particle size range between 125 microns to500 microns.

3. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 or Claim 2 and it is characterized by; containing fine granule volcanic aggregate with minimum 55% Si0₂ maximum 4% Fe₂0₃, maximum 10% total alkali (Na₂0+K₂0), minimum 10% Al₂0₃ in its chemical composition.

4. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing coarse granule volcanic aggregate with particle size range between 500 microns to 4 mm.

5. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 or Claim 5 and it is characterized by; containing coarse granule volcanic aggregate with minimum 55% Si0₂ maximum 4% Fe₂0₃, maximum 10% total alkali (Na₂0+K₂0), minimum 10% Al₂0₃ in its chemical composition.

6. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing calcined diatomite additive with particle size range below 1 mm.

7. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing at least one resistance increasing additive material, preferably volcanic ash.

8. It is the precast composite mortar with inorganic binding system mentioned in Claim 7 and it is characterized by; containing volcanic ash with the particle size between 40 microns to 750 microns.

9. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing at least one filling material, preferably micronized limestone.

10. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing at least one resistance increasing additive material, preferably fine sand.

11. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing at least one strength increasing material, preferably classified raw perlite.

12. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing at least one binding material, preferably cement.

13. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing at least one plasticizer chemical additive.

14. It is the precast composite mortar with inorganic binding system mentioned in Claim 12 and it is characterized by; its binding material containing plasticizer chemical additive maximum 5% by weight.

15. It is the precast composite mortar with inorganic binding system mentioned in Claim 13 or Claim 14 and it is characterized by; its plasticizer chemical additive being melamine.

16. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing at least on polymer additive, preferably silane and/or silicon based polymer.

17. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing at least on coloring agent.

18. It is the precast composite mortar with inorganic binding system mentioned in Claim 1 and it is characterized by; containing volcanic aggregate of 23%-37% by weight, calcined diatomite additive of 2%-5% by weight, modified anhydrite of 2%-8% by weight, alkali glass fiber 0.75-3.5% by weight, binding material of 32%-42 by weight, volcanic ash of 8%-20% by weight.

19. It is the precast composite mortar with inorganic binding system mentioned in Claim 18 and it is characterized by; containing fine granule volcanic aggregate of 8%-l4% by weight, coarse granule volcanic aggregate of l5%-23% by weight.

20. It is the production method for the preparation of the precast mortar with inorganic binding with structural characteristics appropriate for the interior and/or exterior spaces in the construction sector and it is characterized by; containing the process steps of

• mixing at least two materials to be selected from volcanic aggregate, volcanic ash, micronized limestone, fine sand, raw perlite, calcined diatomite additive materials, in a mixing tank in order to form the first mixture, • mixing at least two materials to be selected from cement, modified anhydrite, alkali resistant glass fiber materials, in another mixing tank in order to form the second mixture,

21. It is the production method for the preparation of the precast mortar with inorganic binding mentioned in Claim 20 and it is characterized by; containing a process step of a third mixture containing polymer additive and/or coloring agent ad its addition into the final mixture.

22. It is the production method for the preparation of the precast mortar with inorganic binding mentioned in Claim 20 or Claim 21 and it is characterized by; containing the process steps of moulding and filling.

23. It is the production method for the preparation of the precast mortar with inorganic binding mentioned in Claim 20 or Claim 21 and it is characterized by; containing a step of preliminary humidification for the first mixture.