EP3341346A1 - Lightweight concrete and manufacturing method - Google Patents
Lightweight concrete and manufacturing methodInfo
- Publication number
- EP3341346A1 EP3341346A1 EP15766409.5A EP15766409A EP3341346A1 EP 3341346 A1 EP3341346 A1 EP 3341346A1 EP 15766409 A EP15766409 A EP 15766409A EP 3341346 A1 EP3341346 A1 EP 3341346A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- density
- lightweight concrete
- aggregate
- concrete according
- resistance
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
-
- 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
-
- 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
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/10—Mortars, concrete or artificial stone characterised by specific physical values for the viscosity
-
- 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
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
Definitions
- the object of this invention is a lightweight concrete, in other words, a form of concrete that without undermining its structural properties is light, with the object of the invention also being the manufacturing method for the aforesaid concrete.
- This invention is characterised by the results achieved through the combination of the materials used in the manufacturing process, mainly through the use of an aggregate material with a lower density and specific weight along with other additives that make it a material with sufficient resistance to compression, bending and thermal conductivity, in addition to waterproofing, soundproofing and fire-resistance.
- this invention fall s u nd er the field of concretes and the ir manufacturing methods.
- Concrete is a compound material used in construction, formed essentially by a binder to which particles or fragments of aggregate, water and specific additives are added.
- the binder is most commonly cement (usually Portland cement) mixed with a suitable proportion of water so that a hydration reaction occurs.
- the particles of aggregate depending essentially on their mean diameter, are arid elements (which are classified as gravel , pea gravel and sand).
- the mixture of just cement with sand and water (without the addition of an aggregate) is called mortar.
- Heavy concrete is considered to be that which has a density in excess of 3200 kg/m 3 due to the use of dense aggregates (using protection against radiation), whereas the standard concrete used in structures has a density of 2200 kg/m 3 , and lightweight concrete has a density of 1800 kg/m 3 .
- concrete as it is known at the present time could benefit from a series of improvements, to find a concrete with lower finishing costs, helping thus in adhering wall and floor tiles, that allows for the manufacturing of blocks, panels and is suitable for casting walls, and is also a high-quality thermal insulator with high levels of fire-resistance, thus developing a concrete like the one that is described herein and is duly recorded in the first claim.
- the object of the present invention is a lightweight concrete that offers a lower density than that of other lightweight concretes, and comprises:
- the aggregate material could possibly be manufactured from pumice stone or volcanic material, which cou ld have a specific weig ht of approximately 0.9 kg/dm3, a solid density mode of 2.2 kg/dm3, and porosity levels of approximately 0.25 kg/dm3, offering a hardness level of 6 on the Mohs scale, without counting or producing gasses.
- surfactant material is a substance that exerts an influence through the surface tension on the contact surface between two phases (e.g. two mutually insoluble liquids).
- surfactants are used as emulsifiers, moisteners, detergents or solubilisers.
- the lightweight concrete obtained as a result of the combination of the previous elements has a density of between 250 kg/m3 and up to 1200 kg/m3, depending on the density of the aggregate material used. Based on the aggregate material's density, the resulting density of the concrete will be different, and consequently the usage that it can be given will be different as well.
- the components of the m ixture are not harmful to people or the environment.
- the invented lightweight concrete is ideal for usage in panels for flooring, ceiling and walls, is compatible with all types of finishing, causes minimum waste levels on site, is easy both to transport, and to assemble in elements and structures, and has good fire-resistance, low thermal conductivity, waterproofing and soundproofing.
- the manufacturing method comprises the stages of:
- One preferred embodiment of the invented lightweight concrete consists of a mixture of cement, low-density aggregate, water, surfactants, resins and foams pre-manufactured using the mixer or produced by injecting water, wherein the final density is between 250 kg/m3 and up to 1200 kg/m3.
- the aggregate material is pumice stone, or volcanic material, or clay baked at high temperatures.
- the lightweight concrete has different densities, which range from 250 kg/m3 up to 1200 kg/m3 with the possibility of obtaining sub-ranges of densities that can be used for different purposes: - Densities of 250-600 kg/m3 used between floors, between ceilings, for non-load-bearing walls, as thermal insulation and soundproofing.
- Lightweight concrete with aggregate of volcanic origin has the characteristic of withstanding fire much better and preserving its qualities when faced with the same, and as such the conservation of the metallic structures is ensured when compared to conventional concrete.
- Blocks can be cut using a handsaw.
- the product can be nailed and glued using wood glue.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Building Environments (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
Abstract
Lightweight concrete that is composed of a mixture of cement, low-density aggregate, water, surfactants, resins and foams pre-manufactured with the mixer or produced by injecting water, characterised in that the final density is within a range of between 250 kg/m3 and up to 1200 kg/m3, the low-density aggregate being pumice stone, volcanic material or baked clay; furthermore, for a density of between 300 kg/m3 up to 1 100 kg/m3 it offers resistance to compression of between 0.9 and 14.3 MPa. Lightweight concrete is ideal for usage in panels for flooring, ceiling and walls, is compatible with all types of finishing, causes minimum waste levels on site, is easy both to transport, and to assemble in elements and structures, and has good fire-resistance, low thermal conductivity, waterproofing and soundproofing.
Description
LIGHTWEIGHT CONCRETE AND MANUFACTURING METHOD
DESCRIPTION OBJECT OF THE INVENTION
The object of this invention, as established in the title, is a lightweight concrete, in other words, a form of concrete that without undermining its structural properties is light, with the object of the invention also being the manufacturing method for the aforesaid concrete.
This invention is characterised by the results achieved through the combination of the materials used in the manufacturing process, mainly through the use of an aggregate material with a lower density and specific weight along with other additives that make it a material with sufficient resistance to compression, bending and thermal conductivity, in addition to waterproofing, soundproofing and fire-resistance.
Therefore, this invention fall s u nd er the field of concretes and the ir manufacturing methods.
BACKGROUND OF THE INVENTION
Concrete is a compound material used in construction, formed essentially by a binder to which particles or fragments of aggregate, water and specific additives are added.
The binder is most commonly cement (usually Portland cement) mixed with a suitable proportion of water so that a hydration reaction occurs. The particles of aggregate, depending essentially on their mean diameter, are arid elements (which are classified as gravel , pea gravel and sand). The mixture of just cement with sand and water (without the addition of an aggregate) is called mortar. There are concretes that are produced with different binders other than cement, such as asphalt concrete, which uses bitumen to create the mixture.
"Portland" ® cement is formed by grinding together both the product resulting from cooking a mixture of limestone and clay until sintering, which is given the
name clinker, along with a regulating material for the setting time (dihydrate gypsum).
Heavy concrete is considered to be that which has a density in excess of 3200 kg/m3 due to the use of dense aggregates (using protection against radiation), whereas the standard concrete used in structures has a density of 2200 kg/m3, and lightweight concrete has a density of 1800 kg/m3.
However, concrete as it is known at the present time could benefit from a series of improvements, to find a concrete with lower finishing costs, helping thus in adhering wall and floor tiles, that allows for the manufacturing of blocks, panels and is suitable for casting walls, and is also a high-quality thermal insulator with high levels of fire-resistance, thus developing a concrete like the one that is described herein and is duly recorded in the first claim.
DESCRIPTION OF THE INVENTION
The object of the present invention is a lightweight concrete that offers a lower density than that of other lightweight concretes, and comprises:
- Cement
- Different sized aggregate, depending on density and usage
- Water
- Surfactant
- Resin
- Foam, either pre-manufactured using a mixer or produced by including air
- Additives to avoid the infiltration of water.
The aggregate material could possibly be manufactured from pumice stone or volcanic material, which cou ld have a specific weig ht of approximately 0.9 kg/dm3, a solid density mode of 2.2 kg/dm3, and porosity levels of approximately 0.25 kg/dm3, offering a hardness level of 6 on the Mohs scale, without counting or producing gasses.
The water used in the mixture must be clean, be free of impurities and contain no oils, alkalis, acids, salts, sugar, organic materials or chlorine.
Surfactant material is a substance that exerts an influence through the surface tension on the contact surface between two phases (e.g. two mutually insoluble liquids). Depending on the extent of its dispersion in water, and on the extent of the stabilisation of the micelles or colloids, surfactants are used as emulsifiers, moisteners, detergents or solubilisers.
The lightweight concrete obtained as a result of the combination of the previous elements has a density of between 250 kg/m3 and up to 1200 kg/m3, depending on the density of the aggregate material used. Based on the aggregate material's density, the resulting density of the concrete will be different, and consequently the usage that it can be given will be different as well.
The characteristics of the invented lightweight concrete are:
- It is an ideal concrete for constructions with lower finishing costs (walls do not need plastering, just filling and paintwork).
- It is easy to use when fixing floor and wall tiles.
- It is not necessary to join blocks together with mortar; all that is needed is glue and the joints will be almost invisible.
- In countries in which volcanic material and pumice stones are available, it is an ideal aggregate in order not to "manufacture" materials with low levels of density, for example: "Leca", clay baked at high temperatures, used in Scandinavian countries such as Sweden.
- It is suitable for the manufacture of blocks, panels and for casting walls with pumping equipment.
- It has high thermal insulation levels suitable for building houses in places with low temperatures, as well places with high temperatures.
- It is highly fire-resistant; lightweight concrete is good for protecting metal structures, piping, wiring, etc.
- The components of the m ixture are not harmful to people or the environment.
Therefore, to summarise, due to the low density of the concrete, the invented lightweight concrete is ideal for usage in panels for flooring, ceiling and walls, is compatible with all types of finishing, causes minimum waste levels on site, is
easy both to transport, and to assemble in elements and structures, and has good fire-resistance, low thermal conductivity, waterproofing and soundproofing.
The manufacturing method comprises the stages of:
- Washing the aggregate to separate heavy stones, light stones, remove dust and rinse the aggregate;
- Sifting the material at 0-2 mm - 2-5 mm - 5-9 mm - 9-20 mm in accordance with their usage in different mixtures and densities;
- Adding water that must be clean, free of impurities and contain no oils, alkalis, acids, salts, sugar, organic materials or chlorine;
- Adding the surfactant;
- Adding the cement;
- Mixing all of the components using a drum mixer, which may be either vertical or horizontal, for a period of between 3 minutes and 6 minutes; - Producing foam, either pre-manufactured using the mixer or produced by including air.
Except when indicated otherwise, all of the technical and scientific elements used in this specification have the meaning commonly understood by one with average skill in the art to which this invention belongs. When this invention is put into practice, methods and materials may be used that are similar or equivalent to the ones described in this specification.
Throughout the description and the claims, the term "comprises" and its variants do not aim to exclude other technical characteristics, additives, components or steps. For those skilled in the art, other objects, advantages and characteristics of the invention may be deduced from both the description and the practical use of the invention. PREFERRED EMBODIMENT OF THE INVENTION.
One preferred embodiment of the invented lightweight concrete consists of a mixture of cement, low-density aggregate, water, surfactants, resins and foams pre-manufactured using the mixer or produced by injecting water, wherein the final density is between 250 kg/m3 and up to 1200 kg/m3.
In another possible embodiment, the aggregate material is pumice stone, or volcanic material, or clay baked at high temperatures.
The composition of the cement in a possible embodiment that is approximate and by no means limiting:
- Alite: tricalcium silicate 3CaO»SiO2 (C3S) at 27.9 % by weight
- Belite: dicalcium silicate 2CaO»SiO2 (C2S) at 5.8 %
- Tricalcium aluminate 3 CaO»AI2O3 (C3A) at 2.6 %
- Celite: Tetracalcium aluminoferrite 4CaO»AI2»F2O3 (C4AF)
at 52.7 %
- Magnesium Oxide at 1 .2 %
- Sulphur Oxide at 2.8 %
- The remainder of the materials accounting for a 7 % proportion. Depending on the density of the aggregate material, which is preferably pumice stone or volcanic material, the lightweight concrete has different densities, which range from 250 kg/m3 up to 1200 kg/m3 with the possibility of obtaining sub-ranges of densities that can be used for different purposes: - Densities of 250-600 kg/m3 used between floors, between ceilings, for non-load-bearing walls, as thermal insulation and soundproofing.
- Densities of 600-800 kg/m3 used for blocks and thermal insulation.
- Densities of 800-1000 kg/m3 used for non-load-bearing pre-cast elements.
- Densities of 1 100-1200 kg/m3 used for load-bearing pre-cast elements and for flooring.
The concrete manufactured in this manner has the following functional and structural characteristics that depending on their final density are:
- Resistance to compression depending on density will be:
• Density 300-800 kg/m3 = 0.9 - 4.6 MPa
• Density 800-1 100 kg/m3 = 4.6 - 14.3 MPa
- Resistance to bending: Density 600 kg/m3 = 0.89 MPa
- Fire resistance: Density 400 kg/m3 = 60 degrees C after 90 min.
- Thermal conductivity: Density 600 kg/m3 = 0.093 W/mK
- Waterproofing: Water penetration depth: 25 mm.
- Soundproofing: Constructed panels measuring 15 cm in thickness ensure an acoustic behavioural rating that effectively reduces exterior noises and/or those produced within the property emanating outwards.
- Fire resistance: Lightweight concrete with aggregate of volcanic origin has the characteristic of withstanding fire much better and preserving its qualities when faced with the same, and as such the conservation of the metallic structures is ensured when compared to conventional concrete.
- Blocks can be cut using a handsaw.
- The product can be nailed and glued using wood glue.
- For electrical wiring it easily allows for cutting recesses and milling out grooves for piping. Having thus adequately described the nature of the present invention, as well as how to put it into practice, it must be noted that, within its essential nature, the invention may be carried out according to other embodiments differing in detail from that set out by way of example, which the protection sought would equally cover, provided that the fundamental principle thereof is not altered, changed or modified.
Claims
1 . - A lightweight concrete that is composed of a mixture of cement, low- density aggregate, water, surfactant, resins and foams produced by the mixer or by injecting water, characterised in that the final density is within a range of between 250 kg/m3 and up to 1200 kg/m3, the low-density aggregate being pumice stone, volcanic material or baked clay.
2. - The lightweight concrete according to claim 1 characterised in that for a density of between 300 kg/m3 and up to 1 100 kg/m3 it offers a resistance to compression of between 0.9 and 14.3 MPa.
3. - The lightweight concrete according to any of th e preceding claims characterised in that for a density of 600 kg/m3 it offers a resistance to bending of 0.89 MPa.
4. - The lightweight concrete according to any of th e claims 1 to 2, characterised in that for a density of 400 kg/m3 it offers a fire resistance of 60 °C after 90 minutes.
5. - The lightweight concrete according to any of the claims 1 to 2, characterised in that for a density of 600 kg/m3 it offers a thermal resistance of 0.093 W/mK. 6.- The lightweight concrete according to any of the preceding claims, characterised in that the cement comprises:
- Alite: tricalcium silicate 3CaO»SiO2 (C3S) at 27.9 % by weight
- Belite: dicalcium silicate 2CaO»SiO2 (C2S) at 5.8 %
- Tricalcium aluminate 3 CaO»AI2O3 (C3A) at 2.
6 %
- Celite: Tetracalcium aluminoferrite 4CaO»AI2»F2O3 (C4AF)
at 52.7 %
- Magnesium Oxide at 1 .2 %
- Sulphur Oxide at 2.8 %
- The remainder of the materials accounting for a 7 % proportion.
7.- A method for manufacturing a lightweight concrete according to any of the claims 1 to 6 characterised in that it comprises the stages of:
- Washing the aggregate to separate heavy stones, light stones, remove dust and rinse the aggregate;
- Sifting the material at 0-2 mm - 2-5 mm - 5-9 mm - 9-20 m m in accordance with their usage in different mixtures and densities;
- Adding water that must be clean, free of impurities and contain no oils, alkalis, acids, salts, sugar, organic materials or chlorine;
- Adding the surfactant;
- Adding the cement;
- Mixing all of the components using a drum mixer, which may be either vertical or horizontal, for a period of between 3 minutes and 6 minutes;
- Producing foam, either pre-manufactured using the mixer or produced by including air.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/EP2015/069500 WO2017032412A1 (en) | 2015-08-26 | 2015-08-26 | Lightweight concrete and manufacturing method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP3341346A1 true EP3341346A1 (en) | 2018-07-04 |
Family
ID=54148465
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP15766409.5A Withdrawn EP3341346A1 (en) | 2015-08-26 | 2015-08-26 | Lightweight concrete and manufacturing method |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP3341346A1 (en) |
| JP (1) | JP2018528920A (en) |
| MX (1) | MX2018002186A (en) |
| WO (1) | WO2017032412A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109467374A (en) * | 2018-12-28 | 2019-03-15 | 海南鑫申绿色建筑科技有限公司 | A kind of earthquake-resistant structure plate and preparation method thereof |
| CN113683356A (en) * | 2021-07-17 | 2021-11-23 | 启东海中港建材有限公司 | High-strength concrete with pumice waste residues as aggregate and preparation method thereof |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB749002A (en) * | 1952-12-03 | 1956-05-16 | Aerocem Ltd | Improvements in or relating to coating compositions for walls and other surfaces |
| DE1961043A1 (en) * | 1969-12-05 | 1971-06-24 | Bosch Gmbh Robert | Lightweight concrete of low bulk density, process for its production and construction element made of concrete |
| JPS6360180A (en) * | 1986-08-29 | 1988-03-16 | 小野田エー・エル・シー株式会社 | Manufacture of lightweight concrete |
| IT1229844B (en) * | 1989-04-20 | 1991-09-13 | Tecniche Ind Srl | WATER-REPELLENT AND FIREPROOF THERMAL INSULATION MORTARS WITH HIGH MECHANICAL PROPERTY / SPECIFIC WEIGHT RATIO. |
| JP3158657B2 (en) * | 1992-05-08 | 2001-04-23 | 宇部興産株式会社 | Manufacturing method of low shrinkage lightweight concrete |
| JPH08109080A (en) * | 1994-10-12 | 1996-04-30 | Ask:Kk | Inorganic light heat insulator and its molding |
| JPH0913573A (en) * | 1995-06-27 | 1997-01-14 | Sekisui Chem Co Ltd | Wall panel and manufacture thereof |
| US6290769B1 (en) * | 1999-06-22 | 2001-09-18 | Siplast, Inc. | Lightweight insulating concrete and method for using same |
| DE10137231A1 (en) * | 2001-07-30 | 2003-02-20 | Tubag Trass Zement Stein | Medium-bed mortar for laying large-format floor slabs |
| US8070878B2 (en) * | 2007-07-05 | 2011-12-06 | United States Gypsum Company | Lightweight cementitious compositions and building products and methods for making same |
| WO2009024105A1 (en) * | 2007-08-23 | 2009-02-26 | Christoph Maier | Additive compound for building materials with mineral basis |
| CZ21513U1 (en) * | 2010-08-31 | 2010-11-29 | Satsys Technology A.S. | Maintenance ready-mixed plaster |
| FR3000060B1 (en) * | 2012-12-20 | 2014-12-12 | Saint Gobain Weber | CONCRETE COMPOSITION OR ALTERNATING MORTAR COMPRISING AQUEOUS FOAM |
| FR3004177B1 (en) * | 2013-04-04 | 2015-11-20 | Saint Gobain Weber | INSULATING MORTAR COMPOSITION |
| DE102013226861A1 (en) * | 2013-12-20 | 2015-06-25 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Shaped body made of a lightweight material and process for its preparation and use |
-
2015
- 2015-08-26 EP EP15766409.5A patent/EP3341346A1/en not_active Withdrawn
- 2015-08-26 WO PCT/EP2015/069500 patent/WO2017032412A1/en active Application Filing
- 2015-08-26 MX MX2018002186A patent/MX2018002186A/en unknown
- 2015-08-26 JP JP2018507720A patent/JP2018528920A/en active Pending
Non-Patent Citations (2)
| Title |
|---|
| None * |
| See also references of WO2017032412A1 * |
Also Published As
| Publication number | Publication date |
|---|---|
| MX2018002186A (en) | 2018-06-06 |
| JP2018528920A (en) | 2018-10-04 |
| WO2017032412A1 (en) | 2017-03-02 |
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