WO2020214126A2

WO2020214126A2 - Production method of a construction element and a construction element produced by this method

Info

Publication number: WO2020214126A2
Application number: PCT/TR2020/050323
Authority: WO
Inventors: Timucin Daloglu
Original assignee: Dalsan Yatirim Ve Enerji Anonim Sirketi
Priority date: 2019-04-16
Filing date: 2020-04-15
Publication date: 2020-10-22
Also published as: WO2020214126A3; TR201905667A2

Abstract

The present invention relates to production method of a low-density construction element (1) which has a gypsum-based foam core (2) and surfaces of which are coated with a cardboard or a gauze-like coating material (3), and construction elements (1) which are produced by this method.

Description

PRODUCTION METHOD OF A CONSTRUCTION EUEMENT AND A CONSTRUCTION EUEMENT PRODUCED BY THIS METHOD

Technical Field

The present invention relates to production method of a low-density construction element which has a gypsum-based foam core and surfaces of which are coated with a cardboard or a gauze-like coating material, and construction elements which are produced by this method.

Background of the Invention

Thermal insulation materials and wall materials are particularly the most frequently used construction elements being often used today.

Wall materials can be divided into two in terms of their dry and wet application properties. Wet- applied wall materials essentially consist of prismatic building blocks which are interconnected by means of a mortar. The most commonly used ones are solid or hollow bricks obtained by firing of clay, briquettes obtained from cement and sand/aggregate mixture, or pumice (bims) block by mixture of pozzolanic aggregates such as pumice in order to be lighter. Bricks and pumice blocks are they are classified as heavy construction elements because their densities are more than 1.000 kg/m³ and they are not preferred in general because of seismic concerns. A gas (aerated) concrete with a plenty of air space is a wet-applied building block which is obtained by autoclave curing after blow moulding by adding gas-generating aluminium cake together with cement, lime and silica sand. Although limited, none of wet-applied construction elements have insulation properties except for gas concrete. As the density of gas concrete decreases, its thermal insulation property increases. Gas concrete wall blocks mostly have a density of 300-600 kg/m³ and a thermal conductivity of 0.09-0.19 W/mK. Whereas dry-applied construction elements are boards in the form of a layer being usually thinner than 20 mm which are definitely fixed on wooden or metal carrier construction for example by means of screws. The most commonly used ones are plasterboards both sides of which consist of cardboard coated gypsum core, and are cement-based boards reinforced from surface by net or gauze or from core by wood particle or cellulose. Neither gypsum-based or cement-based boards have thermal insulation properties. Gypsum-based boards have a density of 500-950 kg/m³ and their thermal conductivity values are usually between 0,15-0,28 W/mK. Whereas cement-based boards have a density of 900-1.700 kg/m³ and they may decrease to a thermal conductivity value of 0.35 W/mK minimum.

In particular the plasterboards within the scope of TS EN 520 and ASTM C 1396 standards, all dry wall elements such as cement-based and magnesium-based boards are used upon being fixed onto wooden or steel construction by means of mechanical assembly. In comparison to application of blocks such as gas concrete, more qualified practitioners are needed in application of dry wall elements.

Today, in particular gas concrete, all wet-applied wall materials such as briquette and brick are produced by moulding technique. In a production carried out with this technique, production number is limited due to moulding and demoulding the mortar or cutting the large slab into lower size blocks that will be marketed after moulding. In order to make high number of production, intensive machinery and equipment investment is required. Cement-based boards such as fiber-cement reinforced from core by cellulose among dry-applied construction elements are also produced discontinuously by means of a technique partially similar to the moulding method; for this reason, intensive machinery and equipment are needed for production. Therefore, they are partly expensive compared to cement-based boards having high investment cost and being produced on a continuous belt and particularly expensive compared to plasterboards.

Upon the awareness for the world’s global warming problem has increased especially since the early 1990s, it has been started to make“Global Warming Potential” (GWP) calculations of all emission sources. The amount of energy used during production of construction materials varies greatly by the types of construction materials. Specifically, a research (Tiirkiye’de Yaygin Olarak Kullamlan Yiik Ta§imayan Duvarlann Kiiresel Isinma Potansiyeli (Global Warming Potential of Non-Load Bearing Walls commonly used in Turkey), Asst. Prof. Dr. ( gla Meral Akgiil, ODTTJ, Project no: AGUD05-2013-03-03-2-00-71) conducted in Turkey provides GWP values of walls consisting of dry wall materials together with brick, gas concrete, briquette in kg.C0₂/m² according to equivalent thermal conductivity coefficient. According to this study, a wall including plaster located on both surfaces onto a gas concrete of 10 cm has a GWP value of approximately 22 kg.CO m² value whereas a single-frame single-coat plasterboard wall of 10 cm has a GWP value of approximately 13,5 kg. C0₂/m² value.

The United States patent document no. US6171388, an application in the state of the art, discloses compositions of cardboard coated plasterboard having a low density up to a density at 600 kg/m³ value and a thickness less than 20mm that can satisfy the criteria of ASTM C-36 and C-473.

In the United States market, standard plasterboard density is 600 kg/m³ whereas low density products are marketed in the ranges of 500 kg/m³. These boards are plasterboards both side of which are cardboard coated having 12,5 - 20 mm thickness.

The fact that a gypsum mortar wherein water is mixed by means of a suitable mixer can set in a very short time after being laid between two cardboards on the belt is the reason why plasterboards -which are obtained by continuous production on the tape- are relatively cost efficient. The said short time implies that the gypsum mortar is set before 5 minutes, even preferably before 3 minutes, and it can be brought into a consistency hardness that is cuttable in a desired size. Considering that annual capacity of a medium-size plasterboard plant is 30M m²/year, a production line of approximately 400 meters long is required together with pre-belt preparing and post-belt processing units in case of working with a plaster mortar that can set in 5 minutes. The most important criterion for performing high-capacity production is the setting time of a mortar on a belt. Relatively early setting property of plaster by its nature is the reason why plasterboard the most produced construction element in the world.

Due to the fact that cement sets in quite a long time compared to plaster (more than 12 hours), it has been started to produce cement-based construction elements (boards) almost a century later on an industrial scale compared to gypsum-based construction elements (boards).

The United States patent document no. US3284980, an application in the state of the art, discloses production of Portland cement-based board. It is disclosed in the United States patent document no. US3775143 that setting times are shortened through use of high- alumina cement that sets much faster in comparison to Portland cement, together with Portland cement and plaster. The boards being subject to the said patent document are leaf-like boards having less than 20mm thickness.

The United States patent document no. US4304704, an application in the state of the art, discloses a plaster mortar consisting of expanded perlite additive of plaster and cement with polyvinyl alcohol. The United States patent document no. US6641658 discloses that an acceptable hardness can be achieved by combination of high alumina cement, Portland cement and a small amount of plaster in less than 10 minutes.

The United States patent document no. US2004/0040474 discloses that high alumina cement sets extremely fast with triethanolamine (TEA). The post-dated United States patent document no. US2008/0302276, which belongs to the same applicant, discloses a mortar wherein much more economical Portland cement and fly ash and gypsum are used rather than very expensive mortar having high alumina cement by using sodium trimetaphosphate (STMP) together with TEA, and which sets in less than 7 minutes.

In the patent documents that are briefly described above, it is disclosed that cement- based boards can be continuously produced on a belt in less than 7 minutes in approximately 10 to 20 mm thicknesses at 700-800 kg/m³ densities. Nevertheless, it is seen that low density (preferably less than 600 kg/m³, namely less than 300 kg/m³) board production has not been carried out to date by using cement-based board production. Final products obtained in all above mentioned the patent documents always have a thickness less than 20 mm and they have a leaf-like or board-like shape in terms of their sizes.

The International patent document no. W02013/150148 discloses a mineral foam material based on very low density cement. The said document discloses casting a mortar obtained by use of a foam -which is prepared by using a protein-based foaming agent with a molecular weight of 1.000 to 50.000 Daltons, together with Portland cement, alumina cement, calcium sulphate (raw plaster) and plasticizer- into a mould and it also discloses an insulating material obtained by opening the moulds after 24 hours. The product disclosed in the application has a density of about 500 kg/m³ and it has a thermal conductivity between 0,13 - 0,17 W/mK. Nevertheless, the product disclosed in the said application is obtained by molding technique and therefore it has a high production cost.

The International patent document no. WO2017/093796 and the International patent document no. WO2017/093795 disclose mortars of a cement-based mineral foam insulation material having a density less than 100 kg/m³ and a thermal conductivity value less than 0,045 W/mK value. All these mortars are obtained after 24 hours of moulding and they are not suitable for production on a continuous belt.

The Korean patent document no. KR100760039, an application in the state of the art, discloses a mineral-based insulation material which can be demoulded after quick setting in less than 4 minutes by addition of type III sodium silicate (glass water) to the mixture upon a Portland cement -which has a density less than 240 kg/m³ value and thermal conductivity coefficient ranges of 0,03 W/mK- is mixed with water using an animal protein-based foaming agent. Because the sodium silicate disclosed in this document leads to quick setting that is very difficult to control, it is not suitable for production on a belt.

Summary of the Invention

An objective of the present invention is to realize a method for producing a lightweight and economical construction element on a belt continuously without using a moulding technique, and construction elements such as wall block produced by this method.

Another objective of the present invention is to realize a method for producing a construction element which does not comprise steam treatment with high energy cost such as autoclave curing. Another objective of the present invention is to realize a method for producing a construction element which has a GWP value less than a GWP value for example of 9 kg.C0₂/m² value.

Another objective of the present invention is to realize a method for producing a construction element whereby wastage resulting from breaking and injury during production steps and application are reduced.

Detailed Description of the Invention

“Production Method of A Construction Element and Construction Elements Produced by This Method” realized to fulfil the objectives of the present invention is shown in the figures attached, in which:

Figure 1 is a schematic sectional view of the inventive construction element.

Figure 2 is a schematic view of the production line wherein the inventive construction element is produced.

The components illustrated in the figures are individually numbered, where the numbers refer to the following:

1. Construction element

2. Core

3. Coating material

4. Wall

5. Surface

A. Production line

B . S upport B elt Conveyor C. First coil

D. Mixer

E. Shaper

F. Second coil

BB. Belt

G. Cutting station

H. Priming station

I. Heat treatment station

J. Second cutting station

K. Packaging station

The inventive method for producing a low-density (preferably, a low-density less than 600 kg/m³ value) construction element (1) which has a gypsum-based foam core (2) and the core (2) of which is coated with a cardboard or a gauze-like coating material (3) from its four sides comprises steps of:

feeding a planar coating material (3) by a first coil (C) and then laying it over the support belt conveyor (B);

feeding a gypsum-based wet mortar, which will generate the core (2) by setting in time on the coating material (3) and is prepared upon being mixed in a mixer (D), onto the coating material (3) on the support belt conveyor (B);

bending the sides of the coating material (3) whereon there is mortar, by means of a shaper (E);

feeding another planar coating material (3) from a second coil (C) and then laying it onto the mortar such that the mortar on the coating material (3) is covered up;

obtaining the construction element (1) by continuing to move the intermediate product, that is in a wet mortar form the four sides of which are enclosed by the coating material (3), on the belt (BB) until at least the wet mortar generates the core (2). In the inventive method, the support belt conveyor (B) used at the step of feeding a planar coating material (3) by a first coil (C) and then laying it over the support belt conveyor (B) is configured such that it will prevent the coating material (3) laid on it, from breaking off due to the wet mortar to be fed onto the coating material (3) afterwards. Because wet mortar can be fed from the mixer (D) onto the coating material (3) up to 300 mm thickness, preferably more than 20 mm, in the inventive method; there is a possibility that the wet mortar may break off the coating material in this thickness. However, the coating material (3) that is laid on the support belt conveyor (B) being used in the inventive method prevents mortars with the above- mentioned thickness from breaking off due to their wet densities.

In the inventive method, the coating material (3) enclosing the four sides of the gypsum-based construction element on the belt (BB) may vary by whether the construction element (1) to be produced is requested to show fireproof property or not. A gauze or net made of glass fiber that is brought into a fabric form by means of a woven or non- woven, spunbond or spunlace can be used as the coating material (3) showing fireproof property. The coating material (3) also must show some air- permeable property and have a fiber array that is water resistant or may leak water to a very low degree. Preferably, a glass fiber gauze that is laid by means of wet method and has a weight preferably equal to 30 gr/m² weight or a weight higher than this weight is used as the coating material (3). An E-type glass fiber gauze weighing 50 gr/m² and being currently sold by Johns Manville company can be cited as an example for such glass fiber gauze. Products made of petroleum-derived materials such as polypropylene, polyamide or polyethylene can be preferred as the coating material (3) in production of a construction element (1) requiring no fireproof property. Besides, thick papers and/or cardboards being made of all kinds of cellulose pulp and having a weight more than 50 gr/m² can be used as the coating material (3) in order to reduce the production cost in production of the construction element (1) requiring no nonflammability property and therefore the cost of the construction element (1).

At the step of bending the sides of the coating material (3) whereon there is mortar, by means of a shaper (E); the coating material (3) is bended from its two sides such that the opposing walls (4) making almost 90° angle with the belt (BB) in the shaper (E) will be formed. In a preferred embodiment of the invention, in the shaper (E) also, free ends of the walls (4) formed in this way are bended such that they will also make almost 90° angle with the related walls and face one another. Thereby, at the step of -to be carried out later- feeding another planar coating material (3) from a second coil (C) and then laying it onto the mortar such that the mortar on the coating material (3) is covered up; it is ensured that the coating material laid can settle onto the surfaces (5) obtained by bending the free ends of the walls (4).

The inventive method also comprises the step of cutting the construction element (1), which is obtained from the core (2) upon the wet mortar dries and sets and the coating material (3) covering the four sides of the core (2), into requested sizes by means of suitable cutting tools in a cutting station (G). In a preferred embodiment of the invention, the cutting tools included within the cutting station (G) are tools such as reciprocating wire saw or water jet which are suitable for cutting the construction element without breaking up the construction element.

The inventive method also comprises the step of spraying primer optionally in a priming station (H) onto the construction elements (1) which exit the cutting station (G) upon being cut in requested sizes. When production of a construction element (1) such as a wall block intended to be used outside a building is aimed by means of the said method; due to the fact that highly basic cement mortars may decompose the glass fiber having weak alkali resistance by moisture diffusion and water transfer in the facade whereon the wall block is applied in time in the event of making a cement-based plaster onto the said wall block during application; various mineral, latex, silicone-based primers -particularly acrylic -based- that will be able to cut direct contact of glass fiber and cement mortar are applied onto the coating material (3) in the priming station (H) so as to form a film layer on the surfaces of said coating material (3).

The inventive method also comprises the step of subjecting the construction elements (1) which exit the cutting station (G) upon being cut in requested sizes or the construction elements (1) which optionally exit the priming station (H), to heat treatment in a heat treatment station (I). In a preferred embodiment of the invention, a tunnel-type drying oven is included in the heat treatment station (I) and the heat treatment is carried out by means of the said drying oven.

The inventive method also comprises the step of cutting the construction elements (1) exiting the heat treatment station (I) upon being subjected to heat treatment optionally are brought into a final product size by being cut in a second cutting station (J). In a preferred embodiment of the invention, the construction elements (1) are cut in the said second cutting station (J) by means of a cutter such as saw or so on.

The inventive method also comprises the step of packaging the construction elements (1) exiting the heat treatment station (I) upon being subjected to heat treatment or exiting the second cutting station (J), in a packaging station (K) and then making them ready for shipment.

With the inventive method, it is possible to produce construction elements (1) in the form of a wall block which can be provided in different ambient conditions, namely outside or inside buildings, has different application areas and thickness between 50 to 400 mm quickly and cost-effectively. It is enabled to produce different types of construction elements (1) according to the above-mentioned method by selecting the components of mortar generated in the mixer (D) in accordance with the construction element (1) to be produced.

In a preferred embodiment of the invention, the gypsum-based mortar inside the mixer (D) generating the core (2) by setting on the coating material (3) in time can at least comprise: plaster (calcium sulphate hemihydrate - CASO₄.0,5H₂O) as binder; filling materials selected among pozzolonic products such as expanded perlite or pumice, rottenstone and tuff sand preferably having less than 100 kg/m³ density; hardening accelerators selected among salts such as ground fresh gypsum (calcium sulfate dihydrate) or potassium sulfate/sodium sulfate; fluidizers reducing water demand selected among materials such as poly naphthalene sulfonates, polyacrylates, polycarboxylates, lignosulfanates and melamine sulfanates; any composition providing foam formation particularly foaming agents such as sodium alkyl sulfate and all alkyl-aryl-sulfonate, phenoletoxylate, lignosulfanate, alpha olefin sulfanate, alkyl ether phosphate ester and salts, and sodium lauryl sulfanate or protein-based foaming agents (for example currently known in the market with the trade names of MapeAIR L / LA and Propump 26) having 1000 to 50000 Dalton molecular weight and stronger foam stability; and a proper amount of water.

Apart from the components which have been explicitly mentioned above, the gypsum-based mortar may also comprise other additional materials based on in line with the requirements of changing water repellency or water absorption property and even colouring.

In one embodiment of the invention, the construction element (1) obtained by the above-mentioned method is a wall block which is used outside the buildings. An exemplary composition and properties of the said wall block are given in the following Table 1:

Table 1. Sample of an exterior wall block produced in accordance with the inventive method

In one embodiment of the invention, the construction element (1) obtained by the above-mentioned method is a wall block which is used as a partition wall inside the buildings. An exemplary composition and properties of the said wall block are given in the following Table 2:

Table 2. Sample of an interior wall block produced in accordance with the inventive method

With the inventive method, production of a construction element (1) is carried out continuously on at least one belt (BB) without using a moulding technique causing both long production and high cost in the state of the art by ensuring that the wet mortar generating the core (2) upon the coating material (3) sets on the belt (BB) is enclosed by its four sides and thereby both lightweight and economical wall blocks can be produced.

Due to the fact that the coating material (3) is used during production in the construction element (1) being produced in accordance with the inventive method; it is enabled to keep the loss that may occur in the core minimum by minimizing the breaks to occur in the core (2) during production or application of the construction element (1). Also, the bearing on the wall body where the construction element (1) is applied by nail or dowel being used during application can be enhanced by changing the thickness of the coating material (3). Lastly, fire safety of buildings where the construction element (1) is applied are enhanced by enabling to delay, set back a possible fire due to the fact that the construction element (1) which is produced in accordance with the inventive method contains water inside the mortar generating the core (2) and therefore a certain amount of water is included in the core (2) of the final product. It is possible to develop various embodiments of the inventive production method of construction element (1) and the construction element (1) produced in accordance with this method; the invention cannot be limited to examples disclosed herein and it is essentially according to claims.

Claims

1. A method for producing a low-density (preferably, a low-density less than 600 kg/m³ value) construction element (1) which has a gypsum-based foam core (2) and the core (2) of which is coated with a cardboard or a gauze-like coating material (3) from its four sides comprises steps of:

obtaining the construction element (1) by continuing to move the intermediate product, that is in a wet mortar form the four sides of which are enclosed by the coating material (3), on the belt (BB) until at least the wet mortar generates the core (2).

2. A method (1) according to Claim 1; characterized in that a gauze or net made of glass fiber that is brought into a fabric form is used as the coating material (3).

3. A method (1) according to Claim 2; characterized in that a coating material showing some air-permeable property and also having a fiber array that is water resistant or may leak water to a very low degree, is used.

4. A method (1) according to any of the preceding claims; characterized in that a coating material which is a glass fiber gauze being laid by means of wet method and having a weight preferably equal to 30 gr/m² weight or a weight higher than this weight, is used.

5. A method (1) according to Claim 1; characterized in that products made of petroleum-derived materials such as polypropylene, polyamide or polyethylene are used as the coating material (3).

6. A method (1) according to Claim 1; characterized in that thick papers and/or cardboards being made of all kinds of cellulose pulp and having a weight more than 50 gr/m² is used as the coating material (3).

7. A method (1) according to any of the preceding claims; characterized in that at the step of bending the sides of the coating material (3) whereon there is mortar, by means of a shaper (E); the coating material (3) is bended from its two sides such that the opposing walls (4) making almost 90° angle with the belt (BB) in the shaper (E) will be formed.

8. A method (1) according to Claim 7; characterized in that at the step of bending the sides of the coating material (3) whereon there is mortar, by means of a shaper (E); free ends of the walls (4) formed in this way are also bended such that they will make almost 90° angle with the related walls and face one another.

9. A method (1) according to any of the preceding claims; characterized by the step of cutting the construction element (1), which is obtained from the core (2) upon the wet mortar dries and sets and the coating material (3) covering the four sides of the core (2), into requested sizes by means of suitable cutting tools in a cutting station (G).

10. A method (1) according to Claim 9; characterized in that cutting tools which are tools such as reciprocating wire saw or water jet suitable for cutting the construction element without breaking up the construction element, are used.

11. A method (1) according to any of Claim 9 to 10; characterized by the step of spraying primer optionally in a priming station (H) onto the construction elements (1) which exit the cutting station (G) upon being cut in requested sizes.

12. A method (1) according to Claim 11; characterized in that at the step of spraying primer optionally in a priming station (H) onto the construction elements (1); various mineral, latex, silicone-based primers -particularly acrylic -based- are applied onto the coating material (3) so as to form a film layer on the surfaces of the said coating material (3).

13. A method (1) according to any of Claim 11 to 12; characterized by the step of subjecting the construction elements (1) which exit the cutting station (G) upon being cut in requested sizes or the construction elements (1) which optionally exit the priming station (H), to heat treatment in a heat treatment station (I).

14. A method (1) according to Claim 13; characterized in that heat treatment transaction is carried out by means of a tunnel-type drying oven at the step of subjecting the construction elements (1) to heat treatment in a heat treatment station (I).

15. A method (1) according to any of Claim 13 to 14; characterized by the step of cutting the construction elements (1) exiting the heat treatment station (I) upon being subjected to heat treatment optionally are brought into a final product size by being cut in a second cutting station (J).

16. A method (1) according to Claim 15; characterized in that the construction elements (1) are cut by means of a cutter such as saw at the step of bringing the construction elements (1) into a final product size by cutting them in a second cutting station (J).

17. A method (1) according to any of Claim 15 to 16; characterized by the step of packaging the construction elements (1) exiting the heat treatment station (I) upon being subjected to heat treatment or exiting the second cutting station (J), in a packaging station (K) and then making them ready for shipment.

18. A method (1) according to any of the preceding claims; characterized in that the gypsum-based mortar which is prepared upon being mixed inside the mixer (D) and generates the core (2) by setting in time upon being fed onto the coating material (3) on the belt comprises: calcium sulphate hemihydrate as binder; filling materials selected among pozzolonic products such as expanded perlite or pumice, rottenstone and tuff sand having less than 100 kg/m³ density; hardening accelerators selected among salts such as ground fresh gypsum or potassium sulfate/sodium sulfate; fluidizers reducing water demand selected among materials such as poly naphthalene sulfonates, poly acrylates, polycarboxylates, lignosulfanates and melamine sulfanates; any composition providing foam formation particularly foaming agents such as sodium alkyl sulfate and all alkyl-aryl-sulfonate, phenoletoxylate, lignosulfanate, alpha olefin sulfanate, alkyl ether phosphate ester and salts, and sodium lauryl sulfanate or protein-based foaming agents having 1000 to 50000 Dalton molecular weight and stronger foam stability; and a proper amount of water.

19. A construction element (1) which is an exterior wall block used in facades of buildings that are constructed in accordance with a method according to any of the preceding claims.

20. A construction element (1) which is an indoor wall block used as a partition wall inside the buildings that are constructed in accordance with a method according to any of Claim 1 to 18.