WO2019203762A2

WO2019203762A2 - Low density precast mortar with industrial waste additive

Info

Publication number: WO2019203762A2
Application number: PCT/TR2019/050039
Authority: WO
Inventors: Suat Demir
Original assignee: Anka Vizyon Sinema Yapi Anonim Sirketi
Priority date: 2018-01-31
Filing date: 2019-01-17
Publication date: 2019-10-24
Also published as: WO2019203762A3; TR201801339A2

Abstract

The present invention relates to low density precast mortar containing dimensioned granule semolina and dust from roof tile production wastes with the nature of an industrial waste and/or residue material and dimensioned furnace cinder materials obtained from high furnaces as wastes in iron production, supported by trimmed glass fiber, expanded perlite materials, filling materials and chemical polymers, which has higher water absorption, cracking, stretch, pressure, rotation and impact resistances without any need for iron or steel reinforcement in the concrete mortar, has short setting time, resistant against atmospheric conditions, exhibiting high resistance and performance with respect to heat, sound, water and fire insulation, which can breath and exhibit structural characteristics that are appropriate for the interior and/or exterior space applications in the construction sector, and which can be filled in the pre-prepared various moulds by ready or special air injection machines according to the form to be produced and describes the precast mortar with industrial waste additive which contains waste roof tile, expanded perlite, trimmed alkali resistant glass fiber and PVA protected powder polymer in its formulation and the production method of this formulation developed.

Description

LOW DENSITY PRECAST MORTAR WITH INDUSTRIAL WASTE ADDITIVE

Technical Field

The present invention relates to low density precast mortar containing dimensioned granule semolina and dust from roof tile production wastes with the nature of an industrial waste and/or residue material and dimensioned furnace cinder materials obtained from high furnaces as wastes in iron production, supported by trimmed glass fiber, expanded perlite materials, filling materials and chemical polymers, which has higher water absorption, cracking, stretch, pressure, rotation and impact resistances without any need for iron or steel reinforcement in the concrete mortar, has short setting time, resistant against atmospheric conditions, exhibiting high resistance and performance with respect to heat, sound, water and fire insulation, which can breath and exhibit structural characteristics that are appropriate for the interior and/or exterior space applications in the construction sector, and which can be filled in the pre-prepared various moulds by ready or special air injection machines according to the form to be produced and the production method of such mortar.

The present invention does not contain any toxic and allergenic materials which threaten or are harmful for human health.

Prior Art

In the state of the art, there are concrete products with glass fiber reinforcement and concrete element products with specially designed geometric forms used in the structural fa9ade design and production in the construction industry. Fiber reinforced concretes which were defined as precast exterior fa9ade and which were used in the building applications in the world since l970s were started to be used in Turkey since l980s. The hydraulic binding product containing cement, aggregate and water is called concrete and the concrete obtained by addition of natural and artificial materials with irregular fiber structure, to the concrete prepared is called fiber reinforced concrete. Today, the precast building elements obtained by addition of this concrete derivative, increase the deadweight of the building they are applied due to the heavy unit weight of the aggregate materials in the composition (1900-2400 kg/m ) and cause the formation of significant thermal bridges on the application surfaces. Together with this, the difficulties in the connection and installation functions are inevitable within the context of weight measurement. The precast products which are deformed rapidly specifically under the exterior atmospheric conditions are frequently used in the sectoral applications due to their structural composition. Although the exterior fa9ade precast applications have positive effects on the external visuality and the architectural arrangements of the buildings, some technical features required in the materials, which shall be used in the exterior fa9ade applications under current conditions, are not satisfied sufficiently, when the material structures are technically examined. Within this context, it is very important that it has a low weight, that it does not load weight on the building at considerable scales, is not affected by the UV rays of the sun, it has a composition which does not decompose under atmospheric conditions, acid, base and salty mediums, contributes high value added to the thermal and acoustic comfort conditions in the area it is applied and has breathing properties.

Within the frame of the technologic methods being developed, low density precast products achieved by the use of industrial wastes and/or residue materials as the mortar component in the production of exterior fa9ade precast elements with low unit weight, are not a type of product which is commonly seen. The use of material derivatives which can be qualified as an industrial waste and/or residue as a raw material or an additive in an industrial product after recycling is certainly very important for economic gains as well as for production of environmental friendly products.

In the state of the art, the patent application no TR 201617072, with the title“Insulated Light Masonry Building Blocks and Developments in the Production Method of This Product” describes the insulated light masonry building blocks which can be used in all the buildings for which insulation is desired, which can easily perform the applications such as block wall building, precast panel production and installation or on-site casting, which do not require isolation and which provide heat and sound insulation, reduction in the building loads, where ash is used as industrial waste, and which contains cement, foam agent, EPS (Expanded polystyrene foam) beads and also describes the production method of this product.

In the current examinations, it is seen specifically in the roof tile productions in the construction products sector that the tile wastes to form during the processes are not recycled and used in the production of other products. Likewise, high furnace cinders to form as waste materials in the high furnaces during the iron production are also not used and these are collected at outdoor waste areas and result in large volume of waste materials. Due to the technical properties and material characteristic structures, the use of such derivative materials in an industrial product after recycling shall create value added and shall enable the development of innovative products. Moreover, the precast products, which contain such wastes/residue materials in its composition, are not also seen in sectoral uses.

On the other hand, it is very important to provide lightness in the precast product to be used in the building designs and applications and the light weight of the product is directly related to the low density value used in the production. Within this context, producing low density precast mortar by combining the natural perlite materials subjected to thermal processing at high temperature values (850°C and above) with the expanded perlite materials with high porosity and low unit weight and these wastes/residue materials can be identified as a significant innovative material today.

Description of the Invention

The purpose of the invention is to obtain low density precast mortar containing dimensioned granule semolina and dust from roof tile production wastes with the nature of an industrial waste and/or residue material and dimensioned furnace cinder materials obtained from high furnaces as wastes in iron production, supported by trimmed glass fiber, expanded perlite materials, filling materials and chemical polymers, which has higher water absorption, cracking, stretch, pressure, rotation and impact resistances without any need for iron or steel reinforcement in the concrete mortar, has short setting time, resistant against atmospheric conditions, exhibiting high resistance and performance with respect to heat, sound, water and fire insulation, which can breath and exhibit structural characteristics that are appropriate for the interior and/or exterior space applications in the construction sector, and which can be filled in the pre-prepared various moulds by ready or special air injection machines according to the form to be produced. When the expanded perlite materials are classified at different grain sizes, they play the role of pore former in the matrix structure of the mortar and also as an inorganic light filling element. The high porosity of these materials enables the production of the precast products with high heat, sound, temperature resistance and high breathability performance. Moreover, the innovative precast product forms created by appropriate design mortar combinations supported by roof tile semolina waste, high furnace cinder, expanded perlite components and fiber+chemical additives easily provide for many of the performance criteria that are required in the application areas of the buildings. In addition to the heat and sound insulation performances of the building elements produced with these material derivatives, their resistance values against fire and hygienic properties also exhibit very high values. The new generation, low density precast products to be produced also provides ease of application in the high-rise building projects. Besides this, it also increases the building’s resistance against earthquakes since it considerably decreases the dead weight values due to the traditional high density precast use. This fact also provides the development of new derivative panel, plate and/or sheet products for the construction industry. With these mortar combinations, it is possible to produce any surface textures and forms by various moulds such as wood, polyester, steel, rubber- silicone. Moreover, precast fa ade panels in the form of a shell, which are removed out of the moulds with a thickness between 1.0 - 2.0 cm, are made very rigid by the support of carrier steel box profiles and the system carrier carcass detail is connected to the precast shell with flexible anchorage elements by selecting appropriate sections according to the dimensions of the precast elements. In addition, the precast products can be produced at any size based on the project details and the applicability of the installation.

The product in the present invention, which can easily be used as special design mortar in the production of the precast products to be applied with different geometric designs specifically on the exterior facades of the buildings in the construction sector, eliminates the disadvantages mentioned above and provides precast applications which are earthquake resistant and has higher durability. The invention provides significant saving with respect to the labor, time, material, construction techniques, energy consumption.

Detailed Description of the Invention

The developed formulation of the low density precast mortar with industrial waste additive of the present invention, with structural properties in compliance with the interior and/exterior space applications, which can be filled in the pre-prepared various moulds by ready or special air injection machines according to the form to be produced, contains waste roof tile, expanded perlite, trimmed alkali resistant glass fiber and PVA protected powder polymer.

The roof tile used in the developed formulation of the precast mortar with industrial waste additive is completely obtained from the wastes of well fired roof tile production by breaking and sifting processes. There may be foreign materials within its structure, such as coal dusts, soil and stone components. The color of this material may vary from light colors to dark colors based on the firing temperature applied on the roof tile in the factory.

Another characteristic of the precast mortar of the present invention is the availability of the waste roof tiles in two different particle sizes. The resistance of the light precast mortar to the weather conditions and flexibility is increased by the formulations developed thanks to two different particle sizes as granule roof tile waste and roof tile dust. The granule roof tile semolina is classified within the dimension range of l-2mm, the roof tile dust is classified within the dimension range of 500 micron- lmm.

Expanded perlite used in the precast mortar with industrial waste additive formulations developed is subjected to expansion under high temperatures. Another characteristic of the invention is the use of materials with two different density values and different particle sizes which are defined as expanded granule perlite and expanded powder perlite. Accordingly, the lightness of the mortar, heat, sound and fire insulation characteristics are provided and also, the breathability of the product (formation of vapor diffusion capability) is achieved. Expanded granule perlite is classified within the dimension range of 500 microns - 3mm and the density varies between 60-l80kg/m . Expanded powder perlite is classified below the dimension of 500 microns and the density of the material varies between the range of 40-140 kg/m³.

Trimmed alkali resistant glass fiber used in the precast mortar with industrial waste additive formulations developed is used so that the maximum fiber length is 6 mm in order to increase bending, impact and tensile strengths of the hardened low density precast mortar. Trimmed alkali resistant glass fiber is the glass fiber with high alkali resistance, is compatible with the other components in the precast mortar mixtures and its binder Type has H High bundle binding.

In order to improve the adhesive and bonding texture features of the low density precast mortar,“PVA protected powder polymer” that can be harmoniously used with the cement- based mixtures, is used. The powder polymer additive used in the present invention is vinyl acetate-veova-acrylate which is polyvinyl alcohol (PVA) protected powder polymer. The most important characteristic of the polymer is that it can be used at low film formation temperatures and in modified mixtures containing hydraulic binder. It is influential in increasing the application time of the mortar and it decreases the water volume used in the mixtures, accordingly raises the final resistance values of the product. Together with this, it increases the operability feature of the mortar and also raises the water resistance. Also, it enables water insulation features thanks to the high water repelling qualities provided to the mortar. Another characteristic of the precast mortar with industrial waste additive of the present invention is that it contains furnace cinder material, which is an industrial waste material resulting from the process of obtaining iron from iron ore in the high temperature melting furnaces, classified as maximum 500 microns of particle size after breaking and grinding. The process of obtaining iron from iron ore is usually performed at furnaces which are called high furnaces and the iron oxide in the ore is converted into iron state. Melted iron is collected at the bottom part of the furnace. With the effect of the heat the substances such as calcium oxide in the limestone and silica and alumina in the iron ore form a melted group and are collected at the bottom section of the furnace. When this cinder material is taken out of the furnace, its temperature is over about l500°C and is in melted state and when water is poured or it is cooled rapidly with any other method, they become granules like coarse sand particles. Due to rapid cooling, the structure of the cinder is amorphous. This state of the cinder is called granule high furnace cinder. This granule cinder material can be broken and its dimensions can be reduced afterwards. The furnace cinder is an important component for the present invention and it increases the resistance in the cement-based light precast mortar and also is a good filling material thanks to its pozzolanic characteristic. The furnace cinder also reduces the water absorption capability of the light precast mortar by its low water absorption feature. At least one binder material is used as the main binder material in formation of the matrix structure of the low density precast mortar. The binder material used is preferably cement, more preferably Portland cement.

At least one filling material, preferably micronized dolomite with grain size classified as 5 microns, is used in the precast mortar of the present invention. Micronized dolomite is obtained from natural mineral rock containing calcium and magnesium carbonate in its composition, by breaking, sifting and grinding processes. Its chemical composition is CaMg(C0₃)₂. Micronized dolomite is used as the filling material in the light precast mortar mixture within the scope of the present invention and it is a material which improves the resistance of the hardened mortar against the high temperatures, thanks to the magnesium content within its composition. It is an additive component which balances the resistance of the mortar following the hardening and the chemical correspondence of the matrix structure.

At least one pH balancer, preferably slaked powder lime can be used in the precast mortar of the present invention. Ideal slaked powder lime for the production of light precast mortar should at least have 84% Ca(OH)₂ content with 70 microns to 250 microns grain size range, fineness maximum between the range of 3-10%, ignition loss not exceeding maximum 8% and with S0₃ content of maximum 1% in its structure. Preferably CL 90 slaked powder lime serves as pH balancer in the mortar obtained within the scope of the present invention.

A high rate of plasticizer material to reduce the water is added to the mortar during mixing, on condition not to exceed 1,5% of the cement mass, in order to develop the characteristics of the low density precast mortar in its fresh and/or hardened state, to enable the production of high performance precast elements. Melamine in its powder form, which reduces the mixture water and provides a high level of fluidity, and which can even be used at low temperatures, is very appropriate plasticizer to be used in cement-based materials. It has a chemical effect which provides considerable reduction of water volume without changing the consistency in the low density precast mortar composition or increases the precipitation/diffusion without changing the water volume or provides both.

Another characteristic of the precast mortar with industrial waste additive of the present invention is that it contains at least one water repellent material in its structure, preferably sodium oleate. Following the hardening of the low density precast mortar, Sodium Oleate in powder form, compatible with the cement binder mortar mixtures with lime additive can also be used, which covers the outer surface of the mortar with hydrophobic groups in order to reduce the capillary water absorption capacity of the matrix and increase the water resistance. Sodium oleate fatty acids mixture is known as sodium salt and generally it is in the form of white powder. Sodium oleate repels the water contacting the outer surface of the water by creation of a low energy surface and provides a very fine water repellent quality for the mortar. Powder paint not to exceed 0.3% of the total mass of the mixture by weight can be added in order to give color to the mortar.

The precast mortar formulations developed contain 17-61% roof tile waste by weight, 28%- 50% binder material by weight, 11-35% expanded perlite by weight, 0.5-4% alkali resistant trimmed glass fiber by weight, 0.2-2% PVA protected powder polymer by weight.

The low density precast mortar with industrial waste additive of the present invention is obtained by mixing the materials mentioned above. The materials and their weights by percentage in a sample structuring of the low density precast mortar with industrial waste additive prepared are given in Table 1.

Table 1 : The materials and their weights by percentage in the content of the low density precast mortar with industrial waste additive Content Usable Percentage by Weight

Granule roof tile semolina 9% - 15%

Roof tile dust 8% - 14%

Furnace cinder 7% - 13%

Binder material 28% - 40%

Micronized dolomite 4% - 10%

Expanded granule perlite 7% - 15%

Expanded powder perlite 4% - 10%

CL90 Slaked powder lime 1.5% - 5.0%

Alkali resistant trimmed glass fiber 0.5% - 3.0%

Plasticizer chemical additive 0.2% - 1.5%

PVA protected powder polymer 0.2% - 1%

Sodium Oleate 0.2% - 1.4%

Powder paint 0.05% - 0.3%

Mixing, weighing, moulding and filling process steps are used as the production method in general for the preparation of the precast mortar with industrial waste additive of the present invention. The production method of the precast mortar with industrial waste additive of the present invention is composed of the following process steps:

• Placing at least two materials to be selected from waste roof tile (granule roof tile semolina and/or roof tile dust), furnace cinder, micronized dolomite and slaked powder lime materials, in a mixing tank in order to form the first mixture/formulation component,

• Placing at least two materials to be selected from binder material (cement) and trimmed alkali resistant glass fiber materials, in a mixing tank in order to form the second mixture/formulation component,

• Placing at least two materials to be selected from plasticizer chemical additive, PVA protected powder polymer, sodium oleate and powder paint materials, in a mixing tank in order to form the third mixture/formulation component,

• Mixing of three mixtures three formulation components in the mixing tank in order to form the final mixture, • Adding the expanded perlite (expanded granule perlite and/or expanded powder perlite) materials in the final mixture.

Another characteristic of the precast mortar developed by the present invention is that it contains the moulding and filling process steps.

In compliance with the technical features and dimension distribution defined in the specification for the production of the low density precast mortar with industrial waste additive mentioned in the above example (Table 1), five different components granule roof tile semolina, roof tile dust, furnace cinder, micronize dolomite and CL 90 slaked powder lime materials in a ready to use form are placed in a mixing tank in order to obtain a homogenous dry mixture and are mixed for at least 3 minutes and a homogenous mixture is obtained. This mixing process is named as “mixture - G’. Another mixing process is performed by adding binder material, alkali resistant trimmed glass fiber material components in another mixing tank and mixing these for at least 3 minutes in order to obtain a homogenous mixture. In this mixture, it is very important that the fiber reinforcement material is homogenously distributed within the mixture. This mixing process is named as“mixture - II”. The plasticizer chemical additive, OVA protected powder polymer, sodium oleate and powder paint adjusted as based on their percentages within the mixture are added to the third mixing tank, and the mixture is mixed at least for 3 minutes in order to obtain a homogenous mixture and the homogeneity of the materials is provided. This mixing process is named as “mixture - III”. The“mixture - I”, mixture - II” and“mixture - III” obtained are taken into a different mixer tank and are mixed for 2 minutes at low speed and the homogeneity of these three materials is provided. Following this, expanded granule perlite and expanded powder perlite are weighed and added into this mixer at the percentages to be used in the total mixture in order to form the final mixture. Homogenous mixing of these materials is provided at a low speed mixer by mixing for 3 minutes, however, attention should be paid during this mixing so that the expanded perlite materials do not break into pieces and are not crushed in order not to have a volume loss. Following the completion of the mixing process, weighed water to be used in the total mixture which shall provide the easy spread and processable consistency of the mortar, is added to this tank slowly and mixing is continued until a homogenous mortar mixture is obtained. During these mixture processes, it should attentively be observed whether grain alternation and segregation is formed due to the densities of the materials. A mortar medium in which no segregation appears can be named as“concentrated precast mortar”. Following this process, concentrated precast mortar is ready for moulding process. This concentrated precast mortar obtained is filled in the moulds produced of steel, polyester, wood and/or silicone for which the geometry, dimension and shape is designed and homogenous settlement of the mortar in the mould is provided by a vibration unit. Attention is paid so that open surfaces of the moulds filled with mortar are completely smooth following the filling process. These moulds, if required, are kept in a drying oven for at least 8 hours at a temperature of minimum 60-70°C after the filling process and the mortar is cured. Cured concentrated precast mortar is removed from the moulds and the precast product in final scale is obtained. Completely hardened precast products go through the final quality controls, they are packed and final product form is achieved. The production of the low density precast mortar with industrial waste additive which can be used in the interior and/or exterior fa ade applications can be provided by taking the use ranges defined above in the Table 1, within the frame of the mixture components of the mortar and material use percentages.

Precast products in the form of plates can be obtained with the low density precast mortar with industrial waste additive of the present invention, which can be applied up to 20 mm. The unit weight value of the precast products to be produced with the concentrated precast mortar combinations of the present invention, for the product thickness of 10 mm as a hardened mortar product, can vary between 6-11 kg/m2 based on the combination of the mixture applied.

Claims

1. The present invention is precast mortar with industrial waste additive with structural characteristics appropriate for the interior and/or exterior spaces in the construction sector and it is characterized by; containing waste roof tile, expanded perlite, alkali resistant trimmed glass fiber and PVA protected powder polymer.

2. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing granule roof tile semolina with particle dimensions classified between the range of 1 - 2 mm and roof tile dust with particle dimensions classified between the range of 500 microns - 1 mm, as the waste roof tile,

3. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing expanded powder perlite and expanded granule perlite as expanded perlite.

4. It is the precast mortar with industrial waste additive mentioned in Claim 3 and it is characterized by; containing expanded granule perlite classified between the dimension range of 500 microns - 3mm and density between the range of 60 - 180 kg/m .

5. It is the precast mortar with industrial waste additive mentioned in Claim 3 and it is characterized by; containing expanded granule perlite classified below the dimension of

500 microns and density between the range of 40 - 140 kg/m .

6. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing acetate-veova-acrylate as PVA protected powder polymer.

7. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing furnace cinder.

8. It is the precast mortar with industrial waste additive mentioned in Claim 7 and it is characterized by; containing furnace cinder with particle size of maximum 500 microns.

9. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing at least one binder material, preferably cement.

10. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing at least one filling material, preferably micronized dolomite with largest particle size classified as 5 microns.

11. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing at least one pH balancer, preferably slaked powder lime.

12. It is the precast mortar with industrial waste additive mentioned in Claim 9 and it is characterized by; containing a plasticizer chemical additive not to exceed 1.5% of the cement mass.

13. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing at least one water repellent material, preferably sodium oleate.

14. It is the precast mortar with industrial waste additive mentioned in Claim 1 and it is characterized by; containing 17-61% roof tile waste by weight, 28%-50% binder material by weight, 11-35% expanded perlite by weight, 0.5-4% alkali resistant trimmed glass fiber by weight, 0.2-2% PVA protected powder polymer by weight.

15. It is the production method for the preparation of the precast mortar with industrial waste additive and it is characterized by; containing the process steps of

• Placing at least two materials to be selected from waste roof tile (granule roof tile semolina and/or roof tile dust), furnace cinder, micronized dolomite and slaked powder lime materials, in a mixing tank in order to form the first

mixture/formulation component,

• Placing at least two materials to be selected from binder material (cement) and

trimmed alkali resistant glass fiber materials, in a mixing tank in order to form the second mixture/formulation component,

• Mixing of three mixtures / three formulation components in the mixing tank in order to form the final mixture,

• Adding the expanded perlite (expanded granule perlite and/or expanded powder perlite) materials in the final mixture.

16. It is the production method for the preparation of the precast mortar with industrial waste additive mentioned in Claim 15 and it is characterized by; containing the process steps of moulding and filling