WO2020101589A1 - High-strength lightweight concrete composition - Google Patents

High-strength lightweight concrete composition Download PDF

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Publication number
WO2020101589A1
WO2020101589A1 PCT/TR2019/050098 TR2019050098W WO2020101589A1 WO 2020101589 A1 WO2020101589 A1 WO 2020101589A1 TR 2019050098 W TR2019050098 W TR 2019050098W WO 2020101589 A1 WO2020101589 A1 WO 2020101589A1
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Prior art keywords
cement
oxide
concrete composition
aggregate
porphyritic
Prior art date
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PCT/TR2019/050098
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French (fr)
Inventor
Mucip TAPAN
Original Assignee
Pys Proakti̇f Yalitim Si̇stemleri̇ Mühendi̇sli̇k Yapi Sanayi̇ Ve Diş Ti̇caret Anoni̇m Şi̇rketi̇
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Priority to TR2018/17125 priority Critical
Priority to TR201817125 priority
Application filed by Pys Proakti̇f Yalitim Si̇stemleri̇ Mühendi̇sli̇k Yapi Sanayi̇ Ve Diş Ti̇caret Anoni̇m Şi̇rketi̇ filed Critical Pys Proakti̇f Yalitim Si̇stemleri̇ Mühendi̇sli̇k Yapi Sanayi̇ Ve Diş Ti̇caret Anoni̇m Şi̇rketi̇
Publication of WO2020101589A1 publication Critical patent/WO2020101589A1/en

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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions 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
    • C04B28/04Portland cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/08Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding porous substances
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/40Porous or lightweight materials
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Abstract

The invention is related to a lightweight high-strength concrete composition, which contains 15 - 55% superfine quartz sand and/or porphyritic or basaltic rock sand, 35 – 60% regular rock aggregate obtained from porphyritic or basaltic rock, 10 – 70% pumice aggregate and 0 - 2% polypropylene fibre, by weight.

Description

High-Strength Lightweight Concrete Composition
Technical Field
The invention is related to a concrete composition to be used in the construction sector, which is lightweight, which has low thermal conductivity and high compressive strength.
The invention is particularly related to a lightweight high-strength concrete composition, which contains 15 - 55% superfine quartz sand and/or porphyritic or basaltic rock sand (or other fine filler material obtained from other rocks), 35 - 60% porphyritic rock aggregate, 10 - 70% pumice aggregate and 0% - 2% polypropylene fibre, by weight.
Prior Art
Nowadays, various types and grades of concrete are being used. Concrete should be high-strength under pressure and resistant against environmental factors. In order to fulfill these conditions, concrete should be produced according to the rules in the regulations. Current regulations classify concretes having a bulk unit weight of 1440-1840 kg/m3 as lightweight concrete and the ones having 2240-2400 kg/m3 as regular concrete. Artificial or natural slightly coarse or fine aggregates are generally used to produce lightweight concrete. In addition, expanded clay, schist, perlite and such aggregates which are used to obtain porous structures by drying in the rotary kiln are also used. Compressive strength of the lightweight concrete is directly related to the bulk unit weight of the concrete (the compressive strength of the concrete is reduced as the density of the concrete decreases).
In one of the studies in the literature, 28 days compressive strength of the described lightweight concretes is 25.2-37.5 MPa and their bulk unit weight is indicated to be between 1458-1618 kg/m3 (J. Alexandre Bogas, M. Gloria Gomes, Augusto Gomes, Compressive strength evaluation of structural lightweight concrete by non-destructive ultrasonic pulse velocity method, Ultrasonics, Volume 53, Issue 5, 2013, Pages 962-972). In the lightweight concretes developed in this study and other similar studies, heat-treated light aggregates are usually used with high dosages of cement and this process causes the developed lightweight concrete to be produced at high costs. The use of custom- engineered nano material in order to prevent losses in strength is also common. With this invention, the production of the cost-efficient lightweight concrete which has low amount of cement, named as‘’Pumice Concrete”, has very low thermal conductivity (0.1 - 1 W/mK) and has bulk unit weight varying between 1400 - 1900 kg/m3, whose 28 days strength is between (30 - 90 MPa) will be achieved by using fully natural aggregates (fine, superfine or regular aggregates obtained from porphyritic or basaltic rock, pumise and/or perlite, rerecyclable bims).
Application number TR2016/07445 has been encountered as a result of the patent search conducted. In this application, production of a light and cost-efficient wall panel which provides sound and heat insulation is described. The invention comprises the steps of obtaining panels by casting a mixture that contains pumice stone, cement, water and plasticizing admixture in mold and mounting these panels by means of male and female channels; wherein the panels contain installation margins for being mounted on the ceiling by means of custom engineered anchorages. In the said invention, even though a lightweight concrete composition is obtained, there are no improvements on the compressive strength. In this case, a light but nondurable concrete would be produced.
In consequence, due to the above described negativities and the insufficiency of the present solutions with regards to the subject, an improvement in the related technical field is required.
Brief Decription of the Invention
The present invention is related to a lightweight concrete composition which fullfills the above-mentioned requirements, eliminates all the disadvantages and brings some additional adantages.
The primary purpose of the invention is to provide a lightweight concrete composition which is lightweight, and which has regular or high compressive strength and low thermal conductivity.
A purpose of the invention is to prevent thermal bridges frequently seen in constructions by realizing a lightweight concrete composition which has regular and/or high compressive strength and low thermal conductivity, used in the construction sector, especially for the places which are thermal bridges exist (such as building corners and protruding structural members such as ground floors and balconies). Another purpose of the invention is to realize a concrete composition which has a low bulk unit weight and which provides the production of load-bearing walls and/or cavity wall panels which take up less space, which are sustainable and cost-efficient due to the use of light aggreate (pumice and/or perlite) that has not been treated with heat and less cement.
Another purpose of the invention is to realize a concrete composition which can be used in the production of plates which provide fire endurance by preventing the transfer of heat and fire.
In order to fulfill the above-mentioned purposes, the concrete composition, subject to the invention comprises 15 - 55% quartz sand and/or fine aggregate obtained from porphyritic or basaltic rock, 35 - 60% porphyritic or basaltic rock aggregate, 10 - 70% pumice aggregate and 0 - 2% polypropylene fibre, by weight of the total mixture.
In order to fulfill the purposes of the invention, the particle size of the subject porphyritic or basaltic rock fine aggregate in the composition is between 0 - 3,2 mm; the particle size of the subject porphyritic or basaltic rock (coarse) aggregate is 4 - 22,4 mm; the particle size of the pumice aggregate is 0 - 12 mm.
In order to fulfill the purposes of the invention, the sample chemical composition of the mentioned porphyritic or basaltic rock aggregate comprises an average of 41 ,04% S1O2 (Silicium Oxide), 12,99% AI2O3 (Aluminum Oxide), 14,09% Fe203 (Iron Oxide), 10,16% CaO (Calcium Oxide), 9,01 % MgO (Magnesium Oxide) and 5,51 % Na20 (Sodium Oxide), by weight.
In order to fulfill the purposes of the invention, the sample chemical composition of the mentioned pumice aggregate comprises an average of 73.75% S1O2 (Silicium Dioxide), 15,97% AI2O3 (Aluminum Oxide), 2.73% Fe203 (Iron Oxide), 0.2% T1O2 (Titanium Oxide), 0.69 CaO (Calcium Oxide), 1.87% Na20 (Sodium Oxide), 4.27% K20 (Potassium Oxide), 0.06% P2O5 (Phosphor Pentoxide), 0.16% SO3 (Sulphur Trioxide) by weight.
In order to fulfill the purposes of the invention, the total mixture additionally comprises between 15 - 50% cement, between 10 - 30% silica fume, between 8 - 45% water, air- entraining admixture between 1 - 10% of the cement and/or cementitious binder material, plasticizer (regular, super and/or new generation hyper plasticizer) admixture between 1- 10% of the cement and/or cementitious binder material, by weight.
The structural and characteristic features of the inventions and all of the advantages will be understood more evidently from the detailed description below and therefore, the evaluation should be carried out in consideration of this detailed description.
Detailed Description of the Invention
In this detailed description, the high-strength, lightweight concrete composition subject to the invention is described only for the better understanding of the subject, in a way that will not create any limiting effect on the same.
The lightweight concrete composition subject to the invention, also named as‘’PUMICE CONCRETE” basically comprises quartz sand and/or fine sand obtained from porphyritic or basaltic rock, regular concrete aggregate obtained from porphyritic or basaltic rock and pumice aggregate. In the following tables, the chemical composition of the pumice (Table- 1 ) and the chemical composition porphyritic or basaltic rock aggregate (Table-2) is shown. These tables are given as a sample composition from the prepared samples and the chemicals and amounts may vary. The structural thin sectional view of the pumice aggregate used in order to produce the lighweight concrete is shown in Picture 1 and the structural view with electrone microscope in Picture 2 and the petrographical features in Picture 3.
Table-1 : Sample chemical composition of the pumice
Figure imgf000006_0001
Figure imgf000007_0001
Table-2: Sample chemical composition of the porphyritic or basaltic rock aggregate
Figure imgf000007_0002
In the Table-3 below, a sample of chemical composition of the lightweight concrete composition subject to the invention is shown.
Table-3: Sample chemical composition of the concrete
Figure imgf000007_0003
Figure imgf000008_0001
The cement and/or cementitious binder material present in the composition of the concrete composition subject to the invention is composed of a CEM-I cement, a CEM-II cement, a CEM-3 cement, a CEM-4 cement, a CEM-5 cement and/or EN 197-1 cement grade mixtures.
In the composition of the concrete composition subject to the invention, plasticizer (regular, super and/or new generation hyper plasticizer) admixture and/or air-entraining admixture is used percentage by weight of the cement and/or cementitious binder material. The other sample concrete mixtures of the invention (M1 , M2, M3, M4), compressive strength ve bulk unit weights are given below in Table 4.
Table-4: Sample data of the M1 , M2, M3, M4 Concrete chemical compositions
Figure imgf000008_0002
This invention comprises the production of cost-efficient lightweight concrete, which has low amount of cement, named as‘’Pumice Concrete”, has very low thermal conductivity (0.1 - 1 W/mK) and has bulk unit weight varying between 1400 - 1900 kg/m3, whose 28 days strength is between (30 - 90 MPa) by using mainly natural aggregates (fine, superfine or regular aggregates obtained from porphyritic or basaltic rock, pumise and/or perlite, rerecyclable bims)
For this reason, the lightweight concrete composition subject to the invention can be used in all applications which need low thermal conductivity and high compressive strength. For example, in order to decrease the heat conduction (U value) of a double hull reinforced concrete wall (cavity wall, precast double wall) and render it energy-efficient, the thickness of the wall and the thickness of the insulating layer to be used in the interior of the cavity wall should be increased. By using the concrete composition (PUMICE-CONCRETE) subject to the invention, having low thermal conductivity, the thickness of the cavity wall and the thickness of the required insulating layer can be reduced. Since less cement is used in the composition of the concrete composition subject to the invention in comparison to the market, constructing greener, more cost-efficient and sustainable buildings is possible and since the wall thicknesses are smaller, larger spaces are created.
Additionally, the lightweight concrete subject to the invention can prevent thermal bridges by being used in places with thermal bridge problems such as ground floors, building corners designed from the inside out and balconies.
The invention provides the following characteristics:
• The compressive strength of the lightweight concrete composition after 28 days is between 30-90 MPa and the bulk unit weight is between 1400 - 1900 kg/m3.
• Low thermal conductivity,
• Low bulk weight,
• Regular and/or high compressive strength (The weight/compressive strength ratio is lower compared to the lightweight concretes currently produced),
• More durable and sustainable since it has low density,
• Novel aggregate combination to create lightweight concrete (such as pumice and/or perlite and/or expanded perlite),
• Cost-efficient structural lightweight concrete,
• Incombustibility.
This lightweight concrete with low thermal conductivity and regular and/or high compressive strength will be used in various applications such as the following:
• As concrete slabs to be used in thermal insulation blocks of any kind, load-bearing or not load-bearing, that will be produced in order to eliminate thermal bridges,
• In sustainable buildings and structural elements such as cavity walls,
• As a concrete composition which can be used in the production of plates which provide fire endurance by preventing heat transfer and fire,
• When low thermal conductivity characteristics and regular and/or high compressive strength is required in building construction products.

Claims

1. A lightweight concrete composition with low thermal conductivity and high compressive strength to be used in the construction sector, characterized in comprising 15 - 55% quartz sand and/or fine aggregate obtained from porphyritic or basaltic rock, 35 - 60% porphyritic or basaltic rock aggregate, 10 - 70% pumice aggregate and 0 - 2% polypropylene fibre, by weight of the total mixture.
2. A concrete composition according to Claim 1 , characterized by the particle size of the porphyritic or basaltic rock fine aggregate in the composition to be between 0 - 3,2 mm.
3. A concrete composition according to Claim 1 , characterized by the particle size of the porphyritic or basaltic rock aggregate in the composition to be between 4 - 22.4 mm.
4. A concrete composition according to Claim 1 , characterized by; the particle size of the pumice aggregate in the composition to be between 0- 12 mm.
5. A concrete composition according to Claim 1 , characterized in that; the chemical composition of the mentioned porphyritic or basaltic rock aggregate comprises an average of 41 ,04% S1O2 (Silicium Oxide), 12,99% AI2O3 (Aluminum Oxide), 14,09% Fe203 (Iron Oxide), 10,16% CaO (Calcium Oxide), 9,01% MgO (Magnesium Oxide) and 5,51% Na20 (Sodium Oxide), by weight.
6. A concrete composition according to Claim 1 , characterized in that; the chemical composition of the mentioned pumice aggregate comprises an average of 73.75% S1O2 (Silicium Dioxide), 15,97% AI2O3 (Aluminum Oxide), 2.73% Fe203 (Iron Oxide), 0.2% T1O2 (Titanium Oxide), 0.69 CaO (Calcium Oxide), 1 .87% Na20 (Sodium Oxide), 4.27% K20 (Potassium Oxide), 0.06% P2O5 (Phosphor Pentoxide), 0.16% SO3 (Sulphur Trioxide) by weight.
7. A concrete composition according to Claim 1 , characterized in that; the total mixture additionally comprises between 15 - 50% cement and/or cement like binder material, between 10 - 30% silica fume, between 8 - 45% water, air-entraining admixture between 1 - 10% of the cement and/or cement like binder material, plasticizer admixture between 1 -10% of the cement and/or cement like binder material, by weight.
8. A concrete composition according to Claim 7, characterized in that; the cement and/or cementitious binder material present in the composition is composed of a CEM-I cement, a CEM-II cement, a CEM-3 cement, a CEM-4 cement, a CEM-5 cement and/or EN 197-1 cement mixtures.
9. A concrete composition according to Claim 7, characterized in that; the plasticizer admixture raw material is selected from a group comprising normal, super and/or new generation hyper plasticizer admixtures.
PCT/TR2019/050098 2018-11-13 2019-02-14 High-strength lightweight concrete composition WO2020101589A1 (en)

Priority Applications (2)

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TR2018/17125 2018-11-13
TR201817125 2018-11-13

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111960735A (en) * 2020-07-14 2020-11-20 长江南京航道工程局 Lightweight sandy concrete taking waste ultrafine sand as main raw material and preparation method thereof

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110120349A1 (en) * 2009-11-24 2011-05-26 E. Khashoggi Industries, Llc Extruded fiber reinforced cementitious products having stone-like properties and methods of making the same
US20130284069A1 (en) * 2012-04-27 2013-10-31 United States Gypsum Company Dimensionally stable geopolymer compositions and method
EP2930267A1 (en) * 2014-04-09 2015-10-14 Cemex Research Group AG Method for placement of roller compacted concrete (rcc) on a sub-base to produce a concrete pavement
CN106830834A (en) * 2017-01-24 2017-06-13 葛兆明 Cement polymer base high-performance concrete permeable pavior brick and its manufacture method

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110120349A1 (en) * 2009-11-24 2011-05-26 E. Khashoggi Industries, Llc Extruded fiber reinforced cementitious products having stone-like properties and methods of making the same
US20130284069A1 (en) * 2012-04-27 2013-10-31 United States Gypsum Company Dimensionally stable geopolymer compositions and method
EP2930267A1 (en) * 2014-04-09 2015-10-14 Cemex Research Group AG Method for placement of roller compacted concrete (rcc) on a sub-base to produce a concrete pavement
CN106830834A (en) * 2017-01-24 2017-06-13 葛兆明 Cement polymer base high-performance concrete permeable pavior brick and its manufacture method

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111960735A (en) * 2020-07-14 2020-11-20 长江南京航道工程局 Lightweight sandy concrete taking waste ultrafine sand as main raw material and preparation method thereof

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