TR201800610A2 - CEMENT BASED LIGHT PRECAST MORTAR WITH EXPANDED PERLITE AGGREGATE - Google Patents

Abstract

SUMMARY OF THE INVENTION The present invention provides water absorption, cracking, tensile, compressive, rotational and impact resistance to concrete without any iron or steel reinforcement due to the alkali-resistant glass fibers, expanded perlite aggregate materials, fillers and chemical polymers incorporated therein. pre-prepared according to the form to be produced, which takes out quickly in a short time, is highly resistant to outdoor atmospheric conditions, exhibits high resistance and performance in terms of heat, sound, water and fire insulation, is breathable and has structural features suitable for indoor and / or outdoor applications in the construction sector. It is related to the formulation and production method of cement based lightweight precast mortar which can be ready for various molds or can be filled with special air spraying machines; discloses the formulation of the precast mortar containing tile powder, expanded perlite, high alkali resistant cropped glass fiber and vinyl acetate-veova-acrylate (polyvinyl alcohol protecting polymer) and the method of manufacture of the improved formulation.

Description

DESCRIPTION GENLESMIS PERLITE AGGREGATE CEMENT BASED LIGHT PRECAST MORTAR Technical Area This invention includes alkali resistant glass fibers, expanded perlite aggregate materials, filler materials and chemical polymers, without the need for iron or steel reinforcement into the concrete. Water absorption, cracking, tension, pressure, rotation and impact resistance are much higher than normal concrete. It is highly resistant to external atmospheric conditions, takes its cure in a short time, and is resistant to heat, sound, water and In the construction industry, it is breathable and exhibits high resistance and performance in terms of fire insulation. According to the form to be produced, showing structural features suitable for indoor and/or outdoor applications which can be prepared in various pre-made molds or filled with special air blasting machines. It is about the cement-based lightweight precast mortar formulation and production method. The subject of the invention is precast The developed formulation of the mortar is tile powder, expanded perlite, high alkali resistant shredded glass fiber and vinyl acetate-veova-acrylate (polyvinyl alcohol preservative polymer).

Known Technique In the state of the art, glass fiber reinforced concrete and its products in the construction industry concrete element with specially designed geometric forms used in facade design and production There are product types. It is known as precast exterior facade and has been around the world since the 1970s. Fiber reinforced concrete, which is used in construction applications, has been in Turkey since the 1980s. has been put into use. A hydraulic binder product containing cement, aggregate and water is called concrete. It is obtained by adding natural and artificial materials with irregular fiber structure to a prepared concrete. concrete type is called fiber reinforced concrete. Today, this concrete derivative obtained with precast construction elements, high unit weights of aggregate materials in its composition (1900- 2400 kg/mg), both the dead weight of the building it is applied to increase and the application It causes important heat bridge formations on its surfaces. However, the weight measure In this context, difficulties in connection and assembly functions are also inevitable. sectoral In applications, due to their structural composition, they are rapidly deformed, especially in external atmosphere conditions. It is frequently seen that it is included in precast products that can be Exterior precast applications, Although it makes the exterior visuality and architectural arrangement of the buildings positive, it is technically in terms of material structures. When examined, in today's conditions, the materials to be used in exterior applications are sought after. It can also be seen that some technical features are not adequately provided. In this context, especially the unit It has a low weight, does not impose a significant load on the building, is not affected by the UV rays of the sun, It has a composition that is subject to dissolution in acid, base and salt environments under atmospheric ambient conditions, providing high added value to the thermal and acoustic comfort conditions foreseen in the region where it is applied and It is extremely important to carry breathable features.

In order to eliminate these problems, it is necessary to obtain exterior precast elements with low unit weight. The use of expanded perlite aggregate materials has been applied for However, It is extremely important to provide lightness in the precast product to be used in applications, lightness of the product Low unit weight value of the mortar prepared in the production of the product (light) directly related to it. In this context, expansion at high temperature values (850°C and above) High porosity obtained by the expansion of natural perlite materials subjected to the process, unit Extremely low weight materials are important for obtaining lightweight precast mortar combinations. becomes a material. Expanded perlite aggregate materials, in different grain sizes When classified, they are used in the matrix structure of the mortar in which they are used as both a pore Builder and They also act as inorganic light fillers. The high porosity of these materials Precast products with high heat, sound, high temperature resistance and breathability performance It also enables production. In addition, expanded perlite aggregate component mortar forms of combinations created with chemical additives with suitable properties, application in buildings It can easily meet most of the performance criteria that may be needed in their places.

In the state of the art, "Expanded perlite and natural pumice material with number TR20080214O" The invention titled “heat and sound insulation plaster and sap aggregate” obtained by mixing the interior and exterior of buildings prepared for plastering the surfaces, expanded in its structure, perlite and pumice in equal proportions. Heat and sound insulation obtained by mixing straw aggregate, cement and water obtained by mixing explains the plaster.

The inventor, in the state of the art, expanded perlite aggregate cement-based light precast mortars. encountered problems in adhesion and connective tissue properties. To overcome this problem Known for its high water repellent properties in its work with materials with high water resistance. While it positively affects the waterproofing of the materials in the technique, it also negatively affects the workability of the mortar. found it affected. These existing problems are caused by the development of technical properties in precast mortars and encouraged the inventor in the formulation development and production method stages.

Description of the Invention The aim of the invention is to add alkali resistant glass fibers, expanded perlite aggregate materials, iron or steel reinforcement into the concrete thanks to filling materials and chemical polymers without the need for water absorption, cracking, tension, pressure, rotation and impact resistance compared to normal concrete. much higher, sets in a short time, is extremely resistant to external atmospheric conditions, It exhibits high resistance and performance in terms of heat, sound, water and fire insulation, breathable and To be produced, showing structural properties suitable for indoor and/or outdoor applications in the construction industry. Various pre-made molds ready according to the form or with special air blasting machines It is to obtain a cement-based light precast mortar that can be filled.

Another object of the invention is to develop a precast mortar with an extended application time, while at the same time Increasing the final strength values of the product by reducing the amount of water used in the mixtures. is to provide. However, to increase the workability of the mortar and to produce a mortar with high water resistance. is to develop.

In the construction sector, buildings have different geometric designs, especially in exterior environments. It can be easily used in the production of panel, plate and/or plate products to be applied in the form of precast products. This invention product, which can be used, eliminates the disadvantages mentioned above and is energy efficient. It enables high-efficiency building applications. Invention, workmanship, time, It provides significant savings from materials, construction techniques and energy consumption.

Detailed Description of the Invention The subject of the invention is the structural properties suitable for indoor and/or outdoor applications in the construction industry. Developed formulation of precast mortar showing tile powder, expanded perlite, high alkali durable shredded glass fiber and vinyl acetate-veova-acrylate (polyvinyl alcohol preservative polymer) contains.

The tile powder used in the developed precast mortar formulations is completely well-fired tile. classified in the specific size range obtained by crushing and screening from the residues made of aggregates. In the tile dust, such as coal dust, soil and stone component There are foreign substances. An important aspect of the invention is coarse tile dust and fine tile dust. It is the addition of tile powder with two different particle sizes, namely, to the formulation. big tile fine tile powder is used in the size range of 1-2mm, while fine tile powder is used in the size range of 500micr0n-1mm. is used. In formulations developed with tile powder used in two different size ranges The light precast mortar to be obtained thanks to the characteristic structure and particle size of the materials It has been ensured that it is resistant to ambient weather conditions and gains a flexible feature.

Expanded perlite used in the developed precast mortar formulations, 500micron-3mm It is a material classified in size and subjected to high temperature expansion process.

Expanded perlite material suitable for the production of light precast mortar after the expansion process its density varies between 60-180kg/m3 on average. unit volume of this material Ensuring the lightness of the precast mortar to be obtained due to its low mass value, heat, sound and It is one of the basic elements in gaining the fire insulation feature, and at the same time, the product is breathable. It is one of the most effective elements in providing permeability (the formation of vapor diffusion capability).

Cement-based light precast mortar with expanded perlite aggregate is suitable for design, lightness and ease of use. Providing the formability properties, compressive, bending, impact and tensile strength of the mortar. increasing effect, forming spiral and knitted bond structure, providing crack control and long Highly alkaline resistant to chemicals and high temperatures for long-lasting performance durable shredded glass fiber is used. This glass fiber reinforcement is used in concrete over time. By not reacting with alkali elements, thus, the concrete panel made of precast mortar is formed. products, partition panels, exterior elements, cable boxes, drainage channels and Possibility to be used in very different applications such as the production of concrete derivative works for fine arts it provides.

Adhesion and connective tissue properties of cement-based light precast mortar with expanded perlite aggregate. "Powder polymer additive" that can be used in harmony with cement-based mixtures to improve are available. The powder polymer additive used in the formulations subject to the invention is vinyl acetate- veova-acrylate (a powder polymer with polyvinyl alcohol preservative). The most important feature of the polymer; low movie It can be used at forming temperature and in modified mixtures containing hydraulic binder. that it is usable. It is effective in extending the application time of the mortar and used in the mixtures. It helps to increase the final strength values of the product by reducing the amount of water. With this However, problems in the known art by increasing the workability of the mortar and increasing the water resistance is noble. At the same time, due to its high water repellent feature, it provides waterproofing properties. also adds feature.

Another feature of the developed precast mortar is that it contains at least one filler. The mentioned filling material can be selected from the filling materials used in the construction industry in the known art.

Fine raw perlite and/or micronized preferably fine raw perlite and/or micronized fillers are used as fillers for the precast mortar which is the subject of the invention. dolomite is used.

In precast mortars, natural perlite rock, classified in the size range of 125 microns and 500 microns, Natural origin fine raw perlite aggregate obtained by crushing and grinding is used. natural perlite According to the petrographic texture of the rock, generally granular perlite, pumice perlite, devitified perlite, fibrous There are varieties such as perlite and penocrystalline perlite. The perlite used in this invention is It is preferably obtained from the naturally occurring type "fibrous perlite". Fine raw perlite is produced by this invention. is an important component for It is included as filling material. Fine raw perlite, light precast, thanks to low water absorption It also provides an effect that reduces the water absorption ability of the mortar.

Another filler used in the mortars of the invention is the largest particle size of 5 microns. It is classified micronized dolomite. Micronized dolomite, calcium and magnesium in its composition It is obtained by crushing, screening and grinding processes from a natural mineral rock containing carbonate.

Its chemical composition is CaMg(COg)2. Micronized dolomite is a lightweight precast mortar within the scope of this invention. It is used as a filling material in the mixture, and the magnesium content in the composition It is a material that also improves the resistance of hardened mortar against high temperature environment.

An additive that balances the strength after the mortar has hardened and the chemical overlap of the matrix structure. is the component.

Another feature of the light precast mortar which is the subject of the invention is at least one bonding material in its structure. is to be found. The mentioned bonding material is the bonding agent used in the construction industry in the known technique. materials can be selected. As a bonding material for the precast mortar which is the subject of the invention. preferably portland cement is used.

Another feature of the light precast mortar which is the subject of the invention is at least one pH balancing agent in its structure. is to be found. Said pH stabilizing agent is the pH used in the construction industry in the known art. can be selected from the stabilizing materials. pH stabilizing agent for the precast mortar of the invention Preferably, slaked powdered lime is used.

Slaked powdered lime, which can be idealized for the production of light precast mortar, has a minimum Ca(OH)2 content of 84%. fineness modulus in the grain size range of 70 microns to 250 microns, with a maximum range of 3-10% powder with a maximum ignition loss not exceeding 8% and a content of 503 maximum 1% in the form of slaked lime can be used. CL 90 hydrated powdered lime is also obtained within the scope of this invention. It acts as a pH balancer of the mortar.

Another feature of the light precast mortar which is the subject of the invention is at least one plasticizer material in its structure. is to be found. Said plasticizer material is used in the construction industry in the known art. can be selected from the plasticizer materials. Plasticizer for precast mortar which is the subject of the invention Melamine material is preferably used as the material.

Cement-based light precast mortar with expanded perlite aggregate in fresh and/or hardened state. to improve the properties and to enable the production of high-performance precast elements. During the mixing process, a high proportion of water is added to the mortar, not exceeding 1.5% of the cement mass. reducing super plasticizer material is added. Mixture in cement based materials powder, which reduces water and provides high fluidity, is suitable for use even at low temperatures. In its form, melamine material is a super plasticizer. Consistency in light precast mortar composition without changing the amount of water, or without changing the amount of water It provides a chemical effect that increases precipitation/spreading or creates both effects together.

Another feature of the light precast mortar that is the subject of the invention is the presence of expanded powder perlite in its structure. This The precast mortar to be obtained due to the low unit volume mass value of the material It is one of the basic elements in providing lightness and gaining heat, sound and fire insulation properties. and at the same time, the breathability (occurrence of vapor diffusion ability) feature of the product It is one of the most effective elements in providing Expanded powder perlite material, particle size 500 micron classified under and subjected to high temperature expansion process.

Another feature of the light precast mortar, which is the subject of the invention, is at least one water-repellent chemical material in its structure. is to be found. The water-repellent chemical material mentioned is water-repellent used in the construction industry in the known technique. can be selected from the propellant chemical materials. Water repellent chemical for the precast mortar which is the subject of the invention Silane and/or silicone materials are preferably used as material. water repellent chemical The material is cemented to give a water-repellent property after the light precast mortar has hardened. It can be used in powder and/or liquid form compatible with based mixtures.

Another feature of the light precast mortar, which is the subject of the invention; tile powder, expanded perlite, high alkali durable shredded glass fiber, vinyl acetate-veova-acrylate (polyvinyl alcohol preservative polymer), portland cement, micronized dolomite, expanded powder perlite, slaked powder lime, plasticizer material, water It contains repellent chemical material.

The components in the new formulation of the light precast mortar that is the subject of the invention are 17-29% by weight. tile dust at a rate of 7-15% by weight, expanded perlite at a rate of 0.5-3% by weight, high alkali resistant shredded glass fiber, 0.2-1% by weight vinyl acetate-veova-acrylate polymer, 28-40% by weight of portland cement, 4-10% by weight of micronized dolomite, by weight 1.5% plasticizer material, 0.2-1.4% by weight water-repellent chemical material contains. Another feature of the invention; weight of coarse tile powder in the developed formulation between 9% and 15%, between 8% and 14% by weight of fine tile powder in the formulation. is that.

Another feature of the light precast mortar subject to the invention is at least one colored powder coating and/or color in its structure. the presence of pigment. Paint and/or color pigments existing in the prior art are the subject of the invention. can be used in formulations. It can be used optionally to give color to the mortar.

Cement based lightweight precast with expanded perlite aggregate prepared in an illustration of the invention For the mortar, the materials and weight ratios of the mortar are given in Table 1.

USABLE RATIO BY WEIGHT OF CONTENT Coarse tile dust 9%-15% Fine tile powder 8%-14% Fine raw perlite 7%-13% Portland cement Micronized dolomite 4%-10% Expanded perlite 7%-15% Expanded powder perlite 4%-10% CL9O Slaked Powder Lime High alkali resistant shredded glass fiber plasticizer material Powder polymer additive water repellent chemical material Color powder coating and/or Color pigment General mixing in the production method to prepare the precast mortar, which is the subject of the invention, Weighing, molding and filling process steps are used. The subject of the invention is light precast mortar. process steps of the production method; coarse tile powder, fine tile to form a first mix powder, fine raw perlite, micronized dolomite and slaked lime mixing the two materials in the mixing bowl; portland to create a second mix cement is composed of at least two selected glass fiber materials with high alkali resistance. mixing the material in another mixing bowl; to form a third mix plasticizer material, vinyl acetate andove-acrylate polymer, water-repellent chemical material and colored powder Putting at least two materials selected from among the paint materials into another mixing bowl. mixing; The three mixtures formed together in the mixing chamber to form the final mixture. mixing; Expanded perlite and/or expanded powder perlite materials are weighed and the final adding to the mixture; preferably mixed water feeding; Processes of filling the mixture into molds forms. The detailed explanation of the invention in the application phase of the industry is given below.

For the production of cement-based light precast mortar with perlite aggregate in the above-mentioned example in ready-to-use form in accordance with the technical specifications and size distributions defined in the specification. five different mixture components enriched coarse tile powder, fine tile powder, fine raw perlite, A homogeneous mixture of micronized dolomite and CL 90 slaked powder lime is obtained in dry form. It is placed in a mixing bowl in order to mix it and it is mixed for at least 3 minutes to form a homogeneous mixture. mixture is obtained. This mixing process is called “raw material mixing”. Another The mixing process is portland cement, high alkali resistant, in a separate mixing chamber. In order to obtain a homogeneous mixture by adding shredded glass fiber material components, minimum It is mixed for 3 minutes. In this mixture, the fiber reinforcement material is completely homogeneous in the mixture. Distribution is extremely important. This mixing function can also be called "binder and Iif mixing".

It is also adjusted into another third mixing chamber according to the usage rates in the mixture. amounts of plasticizer, powder polymer additive, water-repellent chemical material and colored powder paint. and/or color pigment for at least 3 minutes to obtain a homogeneous mixture. It is mixed and the materials are ensured to overlap with each other. This mixture function is also called "chemical mixture". can be said. The "raw material mixture", "binder and liiC mixture" and "chemical mixture" obtained in this way The mixtures are taken into a separate mixing bowl and mixed for an average of 2 minutes at low speed. homogeneous mixing of these three materials is ensured. Then into this mixer, the total mixture Expanded perlite and expanded powder perlite materials at the rate to be used are weighed and added.

By mixing with a low-speed mixing for an average of 3 minutes, all of these materials are homogeneously mixed. mixing is achieved. However, the volume loss of the expanded perlite materials during this mixing period. Maximum care should be taken not to crumble or crush it in order to prevent it from being crushed. To mix up After the process is completed, the mortar to be used in the total mixture and to be obtained can be easily Weighed water, which will ensure its dispersion and workability, is slowly fed into this chamber and Mixing is continued at low speed until a homogeneous mortar mixture is obtained. this is my wife grain alternation and segregation that may occur due to the densities of the materials in the should be carefully checked. A mortar environment where segregation does not occur, ”light can be called “precast fee”. After this process, the light precast mortar is ready for the molding process. It means it's in position. The light precast mortar obtained after and shaped form designed molds made of steel, polyester, wood and/or silicone It is filled and homogeneous placement of the mortar through the mold is ensured in a vibration unit. refill After the filling process, the open surface of the molds, on which the mortar filling is made, is completely Care is taken to create a flat surface. After filling these molds, the need If it is heard, it should be taken into an oven environment and kept at a minimum temperature of 60-70°C for at least 8 hours. The mortar is allowed to cure by keeping it in the environment. Cured light precast mortar, By removing it from the molds, a precast product is obtained. Precast that has completely hardened products are delivered to the final product form by being packaged after final quality controls. Your mortar mix taking into account the usage intervals defined in terms of components and material usage rates, Cement based with expanded perlite aggregate that can be used in interior and/or exterior applications production of light precast products can be provided.

20 mm with expanded perlite aggregate cement-based light precast mortar form within the scope of the invention. Plate-shaped precast products can be obtained, which can be applied up to thickness. Lightweight in the scope of the invention 10 mm as the hardened mortar product of the precast products to be produced with precast mortar combinations. The unit weight value for the product thickness is 6 - 11 depending on the mixture combination applied. It can vary in the range of kg/m2.

Claims (1)

CLIENTS Invention is a precast mortar with structural properties suitable for indoor and/or outdoor applications in the construction industry. It contains tile powder, expanded perlite, high alkali resistant shredded glass fiber and vinyl acetate-veova-acrylate polymer. It is a precast mortar according to claim 1, its feature is; contain at least one filler. It is a precast mortar in accordance with Claim Z, its feature is; The filling material is selected from fine raw perlite and/or micronized dolomite materials. It is a precast mortar according to claim 1, its feature is; contains at least one bonding material. It is a precast mortar according to claim 4, its feature is; The bonding material is portland cement. It is a precast mortar according to claim 1, its feature is; contains at least one pH stabilizing agent. It is a precast mortar according to claim 6, its feature is; The pH balancing agent is slaked powdered lime. It is a precast mortar according to claim 1, its feature is; contains at least one plasticizer material. It is a precast mortar according to claim 8. Its feature is; The plasticizer material is melamine. It is a precast mortar according to claim 1, its feature is; contains at least one water-repellent chemical material. It is a precast mortar according to claim 10, its feature is; water-repellent chemical material is selected from silane and/or silicone materials. A precast mortar according to claim 1, characterized in that it contains at least one colored powder dye and/or color pigment. It is a precast mortar according to claim 1, its feature is; It contains tile dust in at least two different size ranges, namely fine tile dust in the size range of SOOmicron-lmm and coarse tile dust in the size range of 1-2mm. It is a precast mortar according to claim 3, its feature is; It contains raw perlite in the size range of 125micron-500micron. It is a precast mortar according to claim 3, its feature is; It is a precast mortar according to Claim 1 with a particle size of less than 5 microns. It contains expanded perlite in the size range of 500 micron-Smm. It is a production method for preparing a precast mortar according to any of the above claims, and its feature is; mixing, weighing, molding and filling process steps. It is a precast mortar according to claim 1, its feature is; It contains tile powder, expanded perlite, high alkali resistant shredded glass fiber, vinyl acetate-veova-acrylate polymer, portland cement, micronized dolomite, expanded powder perlite, slaked powder lime, plasticizer material, water repellent chemical material. It is a precast mortar according to claim 18, its feature is; 17-29% by weight of tile dust, 7-15% by weight of expanded perlite, 0.5-3% by weight of highly alkali resistant chopped glass fiber, 0.2-1% by weight of vinyl acetate-veova-acrylate polymer, 28% by weight - 40% portland cement, 4-10% by weight micronized dolomite, 4-10% by weight expanded powder perlite, 1.5-5% by weight slaked powdered lime, 0.2% by weight- It contains 1.5% plasticizer material and 0.2-1.4% by weight water repellent chemical material. It is a precast mortar according to claim 19, its feature is; It contains 9-15% coarse tile powder and 8-14% fine tile powder by weight in the formulation. It is a production method for preparing a precast mortar according to any of the above claims, and its feature is; 0 Mixing at least two materials selected from coarse tile dust, fine tile dust, fine raw perlite, micronized dolomite and slaked powder lime materials in the mixing bowl to form a first mix, 0 Portland cement, high alkali resistant slaked glass to form a second mix mixing at least two materials selected from among the fiber materials in another mixing bowl, o Mixing the three mixtures together in the mixing chamber to form the final mixture, o Weighing the expanded perlite and/or expanded powder perlite materials and adding them to the final mixture, o Preferably feeding the mixture with water, Filling the mixture into the molds. It is not included.