WO2021046601A1 - A composite concrete panel formed of an aerated concrete mixture and method of manufacture - Google Patents
A composite concrete panel formed of an aerated concrete mixture and method of manufacture Download PDFInfo
- Publication number
- WO2021046601A1 WO2021046601A1 PCT/AU2020/050955 AU2020050955W WO2021046601A1 WO 2021046601 A1 WO2021046601 A1 WO 2021046601A1 AU 2020050955 W AU2020050955 W AU 2020050955W WO 2021046601 A1 WO2021046601 A1 WO 2021046601A1
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- WO
- WIPO (PCT)
- Prior art keywords
- panel
- concrete
- cavity
- mixture
- composition
- Prior art date
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/24—Producing shaped prefabricated articles from the material by injection moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
- B28B1/503—Moulds therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0081—Embedding aggregates to obtain particular properties
- B28B23/0087—Lightweight aggregates for making lightweight articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
- B28B3/08—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form with two or more rams per mould
- B28B3/086—The rams working in different directions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
- B28B7/42—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for heating or cooling, e.g. steam jackets, by means of treating agents acting directly on the moulding material
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/02—Selection of the hardening environment
- C04B40/0254—Hardening in an enclosed space, e.g. in a flexible container
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/38—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions wherein the mixing is effected both by the action of a fluid and by directly-acting driven mechanical means, e.g. stirring means ; Producing cellular concrete
- B28C5/381—Producing cellular concrete
- B28C5/386—Plants; Systems; Methods
- B28C5/388—Methods
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/40—Porous or lightweight materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
Definitions
- the present invention relates to a composite concrete panel formed of an aerated concrete mixture and a method of manufacture.
- Panels formed of aerated concrete which are sometimes referred to as cellular concrete or foam concrete, are known but have limited application due to limitations in strength and surface hardness.
- panels formed of aerated concrete can be efficiently and cost effectively formed in a factory.
- Such panels can also be lightweight compared to regular concrete panels, have excellent fire resistance and good sound attenuation properties.
- Hebei One commonly used panel formed of aerated concrete is known as Hebei and which is formed using aerated concrete that is cured in an autoclave under steam. Such a process is commonly referred to as Autoclaved aerated concrete (AAC) and by introducing the panel into an environment of steam, curing can be performed rapidly.
- AAC Autoclaved aerated concrete
- Hebei panels are formed with internal reinforcement to increase their strength, though this adds weight and cost to the panels.
- the lack of strength of a Hebei panel is a limiting factor and another limitation of Hebei panels is their surface hardness, which can be low so that the external surfaces can be prone to damage.
- the lack of strength in an autoclaved lightweight concrete panel can be attributed to weak tensile bonds within the material due to large air bubbles being present.
- concrete surrounding the air bubbles within the material can be stretched too thin at certain places, leading to areas of weakness that can crack, leading to panel disintegration.
- the location of areas of weakness are impossible to identify due to a lack of uniformity of air bubble size.
- the lack of uniformity of air bubble size is thought to arise due to the forming process in which chemical reactions take place within the concrete mixture to generate the gas bubbles within the panel. Unless this process is tightly controlled, the size distribution of gas bubbles within the panel can vary across the panel, leading to areas of weakness.
- a method of manufacturing a composite concrete panel comprising the steps of: forming an aerated concrete composition by adding a foaming agent to a concrete mixture and mixing the composition to substantially evenly distribute the foaming agent through the composition; providing a cavity in which the panel is to be formed; inserting the aerated concrete composition into the cavity; and pressurizing the panel during curing. whereby air bubbles present in the aerated concrete mixture are compressed to a smaller and more uniform size.
- the panel is pressurised by contacting external surfaces of the panel against the cavity during curing.
- sides of the cavity are advanced toward each other to apply pressure to the panel.
- the panel is pressurised to bring the density of the panel to within a range of 300 to 800 kg/m3.
- the panel is pressurised up to approximately 3 atmospheres.
- the method can further include the step of placing an internal core within the cavity.
- the internal core has a porous external surface.
- the internal core may be engaged with a strengthening element.
- the strengthening element may be a rib formed of metal, timber or fibreglass.
- the core is formed of a polymer.
- the polymer may be polystyrene or polyurethane.
- the concrete mixture includes cement, sand, water and the said foaming agent.
- the concrete mixture further includes strengthening additives, which may include epoxy resin.
- the concrete composition can further include foam glass or pumice glass.
- Figure 1 is a cross sectional view of a panel formed according to a preferred embodiment of the invention.
- Figure 2 is a very close cross section of the panel showing air bubbles
- Figure 3 is another very close cross section of the panel showing the air bubble size close to a surface interface.
- a composite concrete panel 10 according to a preferred embodiment of the invention is illustrated in Figure 1.
- the panel 10 is formed of an aerated concrete mixture 12 and has an internal stiffening core 14, though in other embodiments the core may be omitted.
- the panel 10 is pressurised within a mould during manufacturing to reduce the size of air bubbles within the mixture and increase panel strength. Pressurising the panel 10 within the mould during manufacture also increases the surface hardness of the concrete at each surface interface, i.e. an outer surface and an inner surface where the aerated concrete mixture 12 contacts the core 14.
- the panel 10 is pressurised by contacting external surfaces of the panel 10 against a mould cavity during curing.
- walls of the mould may be moveable to squash the panel 10 within the cavity.
- the aerated concrete mixture can be injected under pressure, just like in injection moulding. In such embodiments, complicated moulds with moving parts can be avoided.
- an example of an injection port 20 is illustrated. The inventor has found that the strength of an aerated concrete panel is proportional to the size of air bubbles that are introduced into the mixture 12.
- the inventor believes that on a macroscopic level, it is the thickness of the concrete mixture or walls between the air bubbles that makes a significant contribution to the strength of the panel, due to the prevention of weak tensile bonds at localised locations.
- the sections of concrete between the air bubbles become longer and thinner, and therefore capable of carrying less load to the detriment of the overall strength of the panel.
- Figure 2 whereby the thickness of the mixture 12 between air bubbles 16 is shown, along with the varying thickness of the mixture 12. Owing to this effect, it is important that gas bubbles be evenly distributed within the panel, otherwise areas of weakness can be introduced.
- prior art panels that rely on a chemical reaction to generate gas bubbles, control of the bubble distribution within the panel, and therefore their size once compressed, can be difficult to achieve.
- a foaming agent is introduced into the concrete mixture and the mixture stirred well, prior to the concrete composition being introduced into the mould. This ensures a generally even distribution within the mixture so that once pressurised, the gas bubbles are uniformly small and the strength of the panel improved.
- the foaming agent may be any suitable commercially available foaming agent, organic or chemically derived, that creates air bubbles in the concrete mixture. The amount of air bubbles added to the mixture governs the density of the panel.
- the air bubble size can be reduced and the size of bubbles across the panel made more consistent so that areas of thin concrete between adjacent bubbles and the associated areas of weakness can be avoided so that a designer can more accurately predict the strength of the panel.
- Figure 3 illustrates the size distribution of air bubbles within the mixture toward an interface surface 18 where the mixture contacts the mould and also a second interface surface where the mixture contacts the core 14.
- the surface hardness of the panel 10 increases, providing an external panel surface that is less prone to damage, particularly during transportation. This may allow the panel 10 to be coated with paint or render at manufacture and then transported to a building site, thereby significantly reducing manufacturing costs.
- the internal core 14 has a porous external surface. Another advantage of the present disclosure is that by pressurising the panel 10, greater engagement or bonding between the panel 10 and the internal core 14 is obtained as the mixture is forced into the pores, as can be seen in Figure 3, thereby further adding to the strength of the panel.
- the aerated concrete mixture 12 includes cement, sand, water and a foaming agent or air entrainer that is added prior to the mixture being added to the mould.
- the aerated concrete mixture 12 can further include strengthening additives.
- the strengthening additives can include epoxy resin or fibres for example. Fine particles such as foam glass or pumice glass may also be added to the mixture 12.
- the internal core 14 is provided with a strengthening element (not shown) in engagement with the core 14.
- the strengthening element may be a longitudinal rib running within the core or along an outer edge, and may be formed of metal, aluminium, timber or fibreglass.
- the core 14 is formed of a polymer such as polystyrene or polyurethane.
- the polymer has a porous surface for the reasons discussed above.
- the panel 10 is formed by providing a cavity in which the panel is to be formed, placing the internal core 14 within the cavity, inserting the aerated concrete mixture 12 into the cavity; and pressurizing the panel 10 within the cavity during curing, whereby air bubbles present in the aerated concrete mixture 12 are compressed to a smaller and more uniform size.
- the mixture is pressurised upon injection into a mould, similar to as is done with injection moulding.
- the panel 10 is pressurised by contacting external surfaces of the panel 10 against the cavity during curing. To achieve this sides of the cavity may be advanced toward each other to apply pressure to the panel.
- the panel 10 is pressurised from a lighter density to bring the density of the panel to within a range of 300 to 800 kg/m 3 .
- the pressure may be increased up to 1600 kg/m 3 though it will be appreciated that applying large pressures to the mould can be difficult and expensive.
- the panel is pressurised to 0.5 to 10 atmospheres, preferably approximately 3 atmospheres.
- the described embodiments provide a lightweight panel having a number of uses, particularly in the building industry.
- One example is intertenancy parting walls where non- combustible materials are required, and it is desirable that the walls have good noise attenuation without costing more than previously available panels.
- the described panels can also have high impact resistance
- the described panels may also be used for the construction of a low-cost single storey dwelling.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Architecture (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Civil Engineering (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Laminated Bodies (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Panels For Use In Building Construction (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2020345649A AU2020345649A1 (en) | 2019-09-11 | 2020-09-09 | A composite concrete panel formed of an aerated concrete mixture and method of manufacture |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2019903372A AU2019903372A0 (en) | 2019-09-11 | A composite concrete panel formed of an aerated concrete mixture and method of manufacture | |
AU2019903372 | 2019-09-11 |
Publications (1)
Publication Number | Publication Date |
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WO2021046601A1 true WO2021046601A1 (en) | 2021-03-18 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/AU2020/050955 WO2021046601A1 (en) | 2019-09-11 | 2020-09-09 | A composite concrete panel formed of an aerated concrete mixture and method of manufacture |
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AU (1) | AU2020345649A1 (en) |
WO (1) | WO2021046601A1 (en) |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH0880522A (en) * | 1994-09-12 | 1996-03-26 | Onoda Autoclaved Light Weight Concrete Co Ltd | Composite molded body of carbonated cured body and manufacture thereof |
JPH08208350A (en) * | 1995-02-06 | 1996-08-13 | Asahi Chem Ind Co Ltd | Production of lightweight cellular concrete panel |
JP2000072560A (en) * | 1998-08-27 | 2000-03-07 | Asahi Chem Ind Co Ltd | Lightweight aerated concrete and its production |
JP2000263538A (en) * | 1999-03-16 | 2000-09-26 | Asahi Chem Ind Co Ltd | Laminar cellular concrete plate |
JP2005042323A (en) * | 2003-07-23 | 2005-02-17 | Akiyama Yoko | Concrete structural member and horizontal reinforcement therein |
KR101814653B1 (en) * | 2017-09-27 | 2018-01-03 | 주식회사 하은산업 | Light Concrete Panel for Insulating and Soundproofing and the Manufacturing Method of This |
-
2020
- 2020-09-09 WO PCT/AU2020/050955 patent/WO2021046601A1/en active Application Filing
- 2020-09-09 AU AU2020345649A patent/AU2020345649A1/en active Pending
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH0880522A (en) * | 1994-09-12 | 1996-03-26 | Onoda Autoclaved Light Weight Concrete Co Ltd | Composite molded body of carbonated cured body and manufacture thereof |
JPH08208350A (en) * | 1995-02-06 | 1996-08-13 | Asahi Chem Ind Co Ltd | Production of lightweight cellular concrete panel |
JP2000072560A (en) * | 1998-08-27 | 2000-03-07 | Asahi Chem Ind Co Ltd | Lightweight aerated concrete and its production |
JP2000263538A (en) * | 1999-03-16 | 2000-09-26 | Asahi Chem Ind Co Ltd | Laminar cellular concrete plate |
JP2005042323A (en) * | 2003-07-23 | 2005-02-17 | Akiyama Yoko | Concrete structural member and horizontal reinforcement therein |
KR101814653B1 (en) * | 2017-09-27 | 2018-01-03 | 주식회사 하은산업 | Light Concrete Panel for Insulating and Soundproofing and the Manufacturing Method of This |
Also Published As
Publication number | Publication date |
---|---|
AU2020345649A9 (en) | 2024-03-21 |
AU2020345649A1 (en) | 2023-05-04 |
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