阅读说明：本技术 制造和施加非波特兰水泥基材料的系统和方法 (System and method for making and applying non-portland cement-based materials ) 是由 尤金·詹姆斯·卡马利 安德烈亚斯·施雷尔 罗勃·乔治·本兹 于 2016-11-04 设计创作，主要内容包括：提供一种用于施加建筑材料的系统和方法。该方法可包括在分批和混合装置中混合高炉矿渣材料、矿物聚合物材料、碱基粉末和砂,以产生非波特兰水泥基材料。该方法还可包括将非波特兰水泥基材料通过导管从混合装置输送到喷嘴,并将输送的非波特兰水泥基材料与喷嘴处的液体混合以产生部分液化的非波特兰水泥基材料。该方法还可包括将部分液化的非波特兰水泥基材料气动地施加到表面。(A system and method for applying a construction material is provided. The method may include mixing blast furnace slag material, geopolymer material, alkali-based powder, and sand in a batch and mixing apparatus to produce a non-portland cement-based material. The method may further include delivering the non-portland cement-based material from the mixing device to a nozzle through a conduit, and mixing the delivered non-portland cement-based material with a liquid at the nozzle to produce a partially liquefied non-portland cement-based material. The method may further comprise pneumatically applying the partially liquefied non-portland cement-based material to a surface.)

1. A method of applying a construction material, comprising:

mixing blast furnace slag material, geopolymer material, alkali and sand in a batch and mixing apparatus to produce a non-portland cement-based material;

conveying the non-portland cement-based material from the batching and mixing device to a nozzle through a conduit;

mixing the delivered non-portland cement-based material with a liquid at the nozzle to produce a partially liquefied non-portland cement-based material; and is

Pneumatically applying the partially liquefied non-portland cement-based material to a surface.

2. The method of claim 1, wherein the non-portland cement-based material comprises 4% to 45% (weight percent) geopolymer material.

3. The method of claim 2, wherein the non-portland cement-based material comprises greater than 0% to 40% (weight percent) blast furnace slag material.

4. A method according to claim 3, wherein the non-portland cement-based material comprises 10% to 45% (weight percent) alkali.

5. The method of claim 4, wherein the non-Portland cement-based material comprises 20% to 90% (weight percent) sand.

6. A method according to claim 5, wherein the non-Portland cement-based material includes less than 1% (weight percent) sulphate salts.

7. A method according to claim 6, wherein the non-Portland cement-based material includes no more than 5% (weight percent) calcium oxide.

8. The method of claim 1, wherein the blast furnace slag material comprises one or more of fly ash, kaolin, pozzolan, and granulated slag.

9. The method of claim 1, wherein the base comprises one or more of sodium silicate, alkali hydroxide, and alkali carbonate.

10. A system for applying a construction material, comprising:

a batch and mixing apparatus configured to mix blast furnace slag material, geopolymer material, alkali-based powder and sand to produce a non-portland cement-based material including one or more of:

4% to 45% (weight percent) of a geopolymer material;

more than 0 to 40% by weight of a blast furnace slag material;

10% to 45% (by weight) of a base;

20 to 90% by weight of sand;

less than 1% by weight of sulfate; and

not more than 5% by weight of calcium oxide;

a conduit configured to convey the non-portland cement-based material from the batching and mixing device; and

a nozzle configured to receive the non-portland cement-based material and mix the delivered non-portland cement-based material with a liquid to produce a partially liquefied non-portland cement-based material, wherein the nozzle is further configured to pneumatically apply the partially liquefied non-portland cement-based material to a surface.

11. The system of claim 10, wherein the blast furnace slag material comprises one or more of fly ash, kaolin, pozzolan, and granulated slag.

12. The system of claim 10, wherein the base comprises one or more of sodium silicate, alkali hydroxide, and alkali carbonate.

13. An adhesive mixture comprising:

4 to 45% by weight of volcanic rock;

from greater than 0% to 40% (weight percent) of latent hydraulic hardening material;

10 to 45% by weight of an alkaline component;

20% to 90% by weight of a polymer;

less than 1% by weight of sulfate; and

not more than 5% by weight of calcium.

14. A binder mixture according to claim 13, wherein said alkaline component comprises one or more of sodium silicate, alkali hydroxide and alkali carbonate.

15. A binder mixture according to claim 14, wherein said alkaline component is sodium silicate.

16. A binder mixture according to claim 15, wherein said sodium silicate is one of an aqueous sodium silicate solution, powdered sodium silicate and spray dried silicate.

17. A binder mixture according to claim 13, wherein the sulphate in the binder mixture is in the form of a contaminant.

18. A binder mixture according to claim 13, wherein the sulphate in the binder mixture is less than 0.5% (wt%).

19. A binder mixture according to claim 13 wherein the calcium in the binder mixture is in the form of calcium oxide.

20. A binder mixture according to claim 13 wherein the calcium in the binder mixture is not more than 2% (wt%).

21. A binder mixture according to claim 13, wherein the volcanic rock is volcanic ash.

22. The binder mixture of claim 13, wherein the latent hydraulic material comprises one or more of lignite fly ash, anthracite fly ash, kaolin, and trass.

23. The binder mixture of claim 13, wherein the aggregate comprises one or more of gravel, sand, basalt, perlite, and expanded shale.

24. The binder mixture according to claim 13, wherein the volcanic rock and/or the latent hydraulic material has a blaine value of greater than 3,000.

25. A binder mixture according to claim 13 wherein the aggregates in the binder mixture are from 20% to 70% (weight percent).

26. A binder mixture according to claim 13 wherein the aggregates in the binder mixture are from 20% to 50% (weight percent).

27. A binder mixture according to claim 13 wherein the aggregates in the binder mixture are from 20% to 40% (weight percent).

28. The binder mixture of claim 13 further comprising water.

29. A method of producing a sprayable concrete composition comprising:

mixing one or more of 4 to 45% by weight of volcanic rock, greater than 0 to 40% by weight of latent hydraulic material, 10 to 45% by weight of alkaline component and 20 to 90% by weight of aggregate to produce a dry binder mixture using a dry mixer,

the dry binder mixture is mixed with water at the nozzle to produce a sprayable concrete compound.

30. The method of claim 29 wherein the dry binder mixture comprises less than 1% (weight percent) sulfate.

31. The method of claim 29 wherein the dry binder mixture includes less than 5% (weight percent) calcium.

32. A method of producing a mouldable concrete compound comprising:

mixing one or more of 4 to 45% by weight of volcanic rock, greater than 0 to 40% by weight of latent hydraulic material, 10 to 45% by weight of alkaline component, and 20-90% by weight of aggregate to prepare a dry binder mixture using a dry mixer;

the dry binder mixture is mixed with water using a planetary mixer to produce a moldable concrete compound.

Technical Field

The present disclosure relates to building materials, and more particularly, to methods of making and applying building materials.

Background

Existing methods in the field of sewer renovation and concrete repair and construction may involve the application of shotcrete, which may be pneumatically projected onto a surface in need of repair or construction. The shotcrete includes materials found in base concrete, such as sand, portland cement, and liquids. The shotcrete may be in the form of a dry mix application or a wet mix application at a particular job site. The phrase "dry blending" generally refers to the pneumatic transfer of some or all of the material in a dry state through a hose to a nozzle where an operator can control the application of liquid to the dry mixture prior to projection of the substance. In contrast, the phrase "wet mixing" generally involves transferring previously mixed concrete including liquid through a hose prior to projection.

Some companies have attempted to alter the material composition of sprayed concrete to obtain certain benefits. Thus, some methods may involve the use of geopolymers. However, these materials are often subject to corrosion due to the organic materials inherent in these products. For example,

in its GeoSpay^TMAnd GeoSpray^TMVarious products are produced under the AMS series products. The AMS product can be used as GeoSpray^TMPre-treatment and/or post-treatment applications of the product. GeoSpray is a Portland cement based, containing only a small fraction of geopolymer. The mixture is not acid stable. AMS contains organic matter and is resistant to the effects of acid on portland cement-based concrete, as well as microbial induced corrosion in portland cement-based materials.

Disclosure of Invention

In a first embodiment, a method of applying a construction material is provided. The method includes mixing blast furnace slag material, geopolymer material, alkali-based powder and sand in a batch and mixing apparatus to produce a non-portland cement-based material. The method further includes delivering the non-portland cement-based material from the batching and mixing device to a nozzle through a conduit, and mixing the delivered non-portland cement-based material with a liquid at the nozzle to produce a partially liquefied non-portland cement-based material. The method further includes pneumatically applying the partially liquefied non-portland cement-based material to a surface.

One or more of the following features may be included. In some embodiments, the geopolymer material is at least one of volcanic rock flour or pumice. The base powder may include a silicate. The mixing may be dry mixing. The non-portland cement-based material may be inorganic. Mixing can be carried out on mobile batch and mixing vehicles. The non-portland cement-based material may include at least one of clay, gneiss, granite, rhyolite, andesite, pickelite, potash feldspar, albite, pumice, and zeolite. Mixing may include mixing on a portable gun configured to receive the non-portland cement-based material from the batching and mixing device. The components of the non-portland cement-based material may include about 2500cm²G to 5000cm²Braun fineness number/g.

In another embodiment, a system for applying a construction material is provided. The system may include a batching and mixing device configured to batch and mix the blast furnace slag material, the geopolymer material, the alkali-based powder, and the sand to produce the non-portland cement-based material. The system may also include a conduit configured to convey the non-portland cement-based material from the batching and mixing devices. The system also includes a nozzle configured to receive the non-portland cement-based material and mix the delivered non-portland cement-based material with a liquid to produce a partially liquefied non-portland cement-based material, wherein the nozzle is further configured to pneumatically apply the partially liquefied non-portland cement-based material to a surface.

One or more of the following features may be included. In some embodiments, the geopolymer material is in a volcanic rock dust or pumiceAt least one of (1). The base powder may include a silicate. The mixing may be dry mixing. The non-portland cement-based material may be inorganic. Mixing can be carried out on mobile batch and mixing vehicles. The non-portland cement-based material may include at least one of clay, gneiss, granite, rhyolite, andesite, pickelite, potash feldspar, albite, pumice, and zeolite. Mixing may include mixing on a portable gun configured to receive the non-portland cement-based material from the batching and mixing device. The components of the non-portland cement-based material may include about 2500cm²G to 5000cm²Braun fineness number/g.

In another embodiment, a non-portland cement-based building material is provided. Non-portland cement-based building materials blast furnace slag materials, volcanic rock powder, alkali-based powder and sand. In some embodiments, the alkali-based powder may be a silicate.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will become apparent from the description, the drawings, and the claims.

Drawings

Fig. 1 is a side view of a mobile system configured to batch, mix, and apply a non-cement based material according to an embodiment of the present disclosure;

fig. 2 is a side rear view of a mobile system configured to batch, mix, and apply a non-cement based material in accordance with an embodiment of the present disclosure;

fig. 3 is a flow chart depicting operations consistent with a non-cement based application process in accordance with an embodiment of the present disclosure.

Like reference symbols in the various drawings may indicate like elements.

Detailed Description

Embodiments of the present disclosure relate to building materials having base-activated binders (i.e., not portland cement-based), as well as systems and methods of making and applying the building materials. Although many of the embodiments included herein are discussed in the context of concrete repair, it should be noted that the construction materials described herein may be used in any suitable application. Some of which may include, but are not limited to, sewer rehabilitation projects, any concrete structure subject to acid attack, etc.

Referring to FIG. 1, a mobile batch and mixing vehicle 100 is shown having a plurality of containers, compartments and devices associated therewith. In some embodiments, the vehicle 100 may include a first container 102 that may be configured to store sand or other materials. The storage unit 104 may be configured to store water or other liquids. The vehicle 100 may also include a batching and mixing device 106, which may include multiple components, some of which may include, but are not limited to, a second container 108, an adjustable delivery mechanism 110, and a portable gun 212. As shown in FIG. 2, the portable gun 212 may be connected to the nozzle 214 by a conduit or hose 216.

In some embodiments, the mobile batch and mix vehicle 100 may be configured to batch, mix, and apply non-portland cement-based building materials. The material may be batched and mixed on-board the vehicle (e.g., within the batching and mixing device 106) or batched and mixed prior to being placed within the second container 108. The material may be delivered to the nozzle 214 where it may be mixed with a liquid from the storage unit 104 before being applied to a surface in need of construction or repair. Details of non-portland cement-based building materials are discussed in further detail below.

In some embodiments, the non-portland cement-based building materials described herein may have better strength values, high resistance and non-reactivity to inorganic and organic acids, and additionally high early strength values compared to existing materials. Non-portland cement-based building materials may exhibit improved high temperature resistance, as well as significantly higher strength and durability. In one example, a non-portland cement-based building material may have excellent resistance to strong mineral acids. Furthermore, products made from non-portland cement-based building materials can have excellent compressive strength and very low thermal conductivity. The material may comprise a dry mixture (e.g. binder mixture) of blast furnace slag material, geopolymer material, alkali-based powder and sand in a batch and mixing apparatus to produce a non-portland cement-based material. In some embodiments, the binder mixture may be used to produce a non-portland cement-based material.

In some embodiments, the binder mixture may include 4% to 45% by weight of volcanic rock, 0% to 40% by weight of latent hydraulic material, 10% to 45% by weight of alkaline component selected from one or more of the following group: sodium silicate, alkali hydroxide, alkali carbonate and their mixture, and 20-90 wt% of aggregate. In some embodiments, the binder mixture may include Sulfate (SO) in the form of contaminants₄ ^2-) Its content is less than 1% (weight percentage). In some embodiments, calcium may be included in the binder mixture in the form of calcium oxide (CaO) in an amount of no more than 5 weight percent.

In some embodiments, the non-portland cement-based building material may include various types of geopolymer materials. The geopolymer material may include, but is not limited to, volcanic rock. Thus, the terms "geopolymer material" and "volcanic rock" may be used interchangeably within the scope of the present disclosure. Some of these geopolymer materials may include, but are not limited to, pozzolanic materials that can react with strong bases and mix the mixture with sand and/or gravel. The pozzolan or pozzolanic material may be a synthetic or natural rock made of silica, clay, limestone, iron oxide and alkaline substances, which may be obtained by the action of heat. When combined with calcium hydroxide and water, they can form a bond. The natural pozzolan (volcanic ash) may be a magma, such as volcanic tuff in germany or rhinestone, but may also be a sedimentary rock containing a high content of soluble silicic acid, and sometimes activated alumina (clay). In some embodiments, the pozzolan may be a readily available raw material and may be used as a volcanic or geopolymer material in non-portland cement-based building materials. Natural materials such as volcanic rock or some other may also be used, however, it may be more desirable if very fine powders (e.g. such volcanic rock powders) are used in smaller portions.

In some embodiments, the non-portland cement-based building material may include any number of firesMountain ash materials, some of which may include, but are not limited to, finely ground clay, gneiss, granite, rhyolite, andesite, bitonite, potash feldspar, albite, pumice, zeolites, and the like, and mixtures thereof. These materials may be used in ground form, calcined and/or non-calcined. Additionally and/or alternatively, containing a sufficient amount of reactive (e.g., metastable, glassy) SiO₂And Al₂O₃All raw materials including, but not limited to, ash, pozzolan, slag may also be suitable for use in embodiments of the present invention.

In some embodiments, the non-portland cement-based building material may include a latent hydraulic hardening material. As used herein, latent hydraulic hardening materials may include, but are not limited to, fly ash, kaolin, pozzolans, granulated slag (e.g., blast furnace slag material), and/or mixtures thereof. In one example, fly ash in the form of lignite fly ash and anthracite fly ash can be used. In some embodiments, the pozzolanic material may include an active silicate, such as slag sand or fly ash. In some embodiments, brick dust (fired clay) or fly ash from power plants burning anthracite or lignite may be referred to as synthetic pozzolan. Thus, the term "fly ash" as used herein may refer to non-natural or synthetic pozzolans. In some embodiments, particularly advantageous properties of fly ash can result from an advantageous ratio of silica to alumina to calcium oxide, which can distinguish these species. However, as will be discussed in more detail below, the fly ash may contain a portion of sulfate and/or calcium oxide. Thus, if fly ash is used in the binder mixture, a fly ash containing a specific substance in an advantageous ratio can be used.

In some embodiments, the non-portland cement-based building material may include an alkali powder material and/or various mixed liquids. Some possible mixed liquids may include, but are not limited to, potassium and sodium water glasses, alkali hydroxides, and the like. In some embodiments, the alkali or alkaline component may be sodium silicate in the form of an aqueous sodium silicate solution or sodium silicate in the form of powdered sodium silicate. In some embodiments, sprayed dried silicate may be used. When alkali hydroxides or alkali carbonates are used, they may be used in their liquid form, or in the form of powders or granules.

In some embodiments, SiO-containing₂And Al₂O₃The reaction between the components of (a) and the alkali mixed liquid may result in an aluminosilicate having a steric structure. These framework structures allow the production of building materials that do not require portland cement in the compound.

As mentioned above, the binder mixture and/or components of the binder mixture may include calcium. In some embodiments, calcium may be included in the binder mixture in the form of a portion of calcium oxide (CaO). These CaO moieties in the binder mixture and/or the non-portland cement-based building material may, upon reaction with the aqueous alkali and/or other components, produce calcium silicate hydrate, which may have known unfavorable chemical properties. Furthermore, calcium ions, which are a component of cement-based crystalline structures, often exhibit undesirable solubility, which can lead to weakening of the cement structure over time. Thus, as low calcium as possible can be used. Using SiO in the form of soluble silicic acid₂Iron oxide, Al in the form of aluminate₂O₃And calcium oxide, embodiments of the present invention may be implemented with water soluble silicates or strong bases, thus creating an inorganic binding system with little or no calcium.

In some embodiments, calcium may be included in the binder mixture in the form of calcium oxide (CaO) in an amount of no more than 5 weight percent. In some embodiments, calcium in the form of calcium oxide may be included in the binder mixture at a level of no more than 2% (weight percent). Additionally and/or alternatively, calcium in the form of calcium oxide may be included at a level of no more than 1% (weight percent).

In some embodiments, Sulfate (SO)₄ ^-2) May be included in the binder mixture as a contaminant and/or may be included at a level of less than 1% by weight. Sulfates in the form of salts are environmentally relevant substances. Increasingly, the pollution of sulfate to the environment is caused by agricultural fertilization and waste management. Sulphate has been shown to cause acidification of land and groundwater. Because the solubility in water is generally higher, the water-soluble polymer is easy to be dissolved inMovement in ground water, seepage and surface water currents ultimately increases the effect of acidification around the sulfate-containing material in the waste storage facility. Sulfate is reduced to sulfite by a microbial process, thereby negatively affecting flora and fauna. In some embodiments, the content of sulfate in the binder mixture may be kept as low as possible to at least avoid these negative effects. In some embodiments, Sulfate (SO)₄ ^2-) May be included in the binder mixture as contaminants and/or may be included at a level of less than 0.5 weight percent. In one embodiment, the sulfate may be present in an amount less than 0.25 weight percent.

In some embodiments, the non-portland cement-based building material may include sand. However, other aggregates may also be used. For example, other aggregates that use the binder mixture as non-cement based concrete may include, but are not limited to, gravel, sand, basalt, and the like. Other materials for non-cement based concrete may also be used within the scope of the present disclosure. Additionally, perlite, expanded shale, pumice, or mixtures thereof may also be used in various applications. In some embodiments, the adhesive mixture may comprise 20% (weight percent) to 70% (weight percent) aggregates. Additionally and/or alternatively, the binder mixture may comprise 20% to 50% (weight percent) aggregates. In one embodiment, the binder mixture may contain 20% to 40% (weight percent) aggregates.

In some embodiments, the binder mixture may also contain water. Thus, in one embodiment, a particularly high resistance to various chemicals, in particular to acids, can be demonstrated by a binder mixture consisting of 4 to 45% by weight of volcanic rock (e.g. mineral polymer material), 0 to 40% by weight of latent hydraulic hardening material (e.g. blast furnace slag material), 10 to 45% by weight of alkaline component (e.g. alkali), 20 to 90% by weight of aggregates (e.g. sand) and/or water. In some embodiments, the alkaline component may include sodium silicate, alkali hydroxide, and/or alkali carbonate. Additionally and/or alternatively, adhesive mixingThe material may include Sulfate (SO) in the form of contaminants₄ ^2-) And/or less than 1% by weight of sulfate. In some embodiments, the binder mixture may include calcium in the form of calcium oxide (CaO) in an amount of no more than 5 weight percent.

In operation, the ingredients may be thoroughly batched and mixed (e.g., all or partially at the vehicle 100) and then delivered to the portable gun 212. The non-portland cement-based building material may be conveyed to nozzle 214 by compressed air through conduit 216. In a particular embodiment, potassium silicate may be added at 48% solids and a density of 1,52g/cm³，SiO₂：K₂O (by weight) is 1,14 and some liquid, and is sufficiently mixed within the nozzle 214 for a short time (e.g., less than 1 second) before the partially liquefied mixture can be pneumatically applied to the desired surface.

Embodiments included herein may include mixtures containing some or all of the following: slag (e.g., non-natural pozzolans, basic or latent hydraulic materials), fly ash (e.g., non-natural pozzolans and optional in the formulation), geopolymeric materials (e.g., natural pozzolans and optional ground pozzolans/volcanic rock), alkali/alkali components (e.g., powders or liquids), other liquids including water (optional), sand/gravel or other aggregates. Examples of specific mixtures are provided below, but it should be noted that the specific mixtures provided herein are included as examples only. Many additional and alternative embodiments are also within the scope of the present disclosure.

In one particular example, the non-portland cement-based building material may consist of a mixture of:

1 part of ground granulated blast furnace slag (e.g. latent hydraulic hardening material)
	0.13 parts of volcanic rock powder (such as volcanic rock) or (optionally fly ash or mixture)
0.61 part of potassium silicate, 1,14 parts by weight
	1.35 parts of sand and/or gravel

TABLE 1

In some embodiments, the components of the mixture may have a density of about 2500-²Blaine fineness of/g (Blaine finess). The blaine value is a standardized measure of the extent of comminution of cement. The Blaine value is a specific surface value (cm) measured in a laboratory with a Blaine apparatus²The,/g) is given. For example, standard portland cement, CEM I32.5, has a blaine value of 3,000 to 4,500. In some embodiments, the binder mixture, the volcanic rock and/or the components of the latent hydraulic material may be used in a finely ground state having a blaine value greater than 3,000. In one embodiment, the volcanic rock and/or latent hydraulic material may have a blaine value greater than 3,500. Finely ground components can significantly increase the reaction rate. Finely ground volcanic rock can be processed more easily and can also lead to increased resistance to various chemicals in the finished product, particularly to acids.

In another example, a non-portland cement-based building material may consist of a mixture of:

TABLE 2

In another example, a non-portland cement-based building material may consist of a mixture of:

TABLE 3

In some embodiments, instead of a hydraulic binder, a non-portland cement-based building material or binder mixture may be used resulting from the reaction of 4% -45% (weight percent) volcanic rock, 0% (or more than 0%) to 40% (weight percent) latent hydraulic material, 10% -45% (weight percent) alkaline component and 20% -90% (weight percent) aggregates. In some embodiments, the alkaline component may include sodium silicate, alkali hydroxide, and/or alkali carbonate. In addition, the binder mixture may include Sulfate (SO) in the form of contaminants₄ ^2-) And/or its content is less than 1% (weight percent). In some embodiments, calcium may be included in the binder mixture in the form of calcium oxide (CaO) in an amount of no more than 5 weight percent.

Embodiments of the non-portland cement-based building material produce unexpected results because the alkaline component reacts with the rock dust for a time sufficient to produce a viscous compound. Through multiple tests, it was found that the compound adhered very well on vertical surfaces, established a tight bond and hardened within 3 days, with a compressive strength value higher than 50N/mm²(8000psi)。

In some embodiments, the binder mixture or non-portland cement-based building material may be used in different technical application fields:

dry mortar and sprayed concrete

The dry mortar and stucco mixture can be produced by mixing the dry components. For this purpose, sprayed dried active silicates or alkali hydroxides can be used. Based on this, ready-made mixtures can be produced for spraying concrete.

Aerated concrete

Commercial aerated concrete is a mineral-based autoclaved aerated block building material with an original density of 300kg/m3 to 800kg/m³. Aerated concrete is typically made from raw materials such as lime, hard mortar, cement, water, and silica sand, and may incorporate the characteristics of the support structure and insulation. The high-temperature heat insulation masonry structure can be made of aerated concrete with an integral single-wall structure.

In some embodiments, the production method may include grinding the silica sand until it is finely ground, such as in a gravel mill, with a blaine value greater than 3,000. These ingredients may be combined to form a mortar mixture in a ratio of, for example, 1: 1: 4, simultaneously adding water. In some embodiments, a small portion of aluminum powder or paste may be added to the final suspension. The mortar mixture can be poured into a tank where the metal particulate aluminum forms hydrogen gas in an alkaline mortar suspension. Air bubbles can be obtained which foam the gradually hardening mortar. After 15 to 50 minutes, the final volume can be obtained. At this time, a block having a length of 3 to 8 meters, a width of 1 to 1.5 meters, and a height of 50 to 80 centimeters can be obtained. The solid blocks or blocks may be cut into any desired size using a wire. In some embodiments, these blocks may be cured in steam at a temperature of 180 ℃ to 200 ℃ in a special steam pressure boiler (e.g., autoclave) at a pressure of 10 bar to 12 bar, wherein the material may obtain its final properties after six hours to twelve hours. Chemically, aerated concrete may correspond primarily to the natural mineral tobermorite, but may be a synthetic material.

In addition to low thermal conductivity, building materials can be distinguished by their lack of flammability, so that they can be classified, for example, in european fire class a 1. Modern aerated concrete compositions may contain a mixture of quicklime, cement, sand and water. Depending on the oven-dry density and the ratio of quicklime to cement, the compositions can be distinguished as lime-rich and cement-rich mixtures. In addition, sulfate carriers in the form of hard mortar or stucco may be used to improve the compressive strength and shrinkage properties due to the development of improved crystalline "house-of-cards" structures in tobermorite. Due to these findings, the addition of sulphate carriers in the form of hard mortar/stucco has proven beneficial in production in the last decade and is therefore currently a component of all aerated concrete compositions.

By adding a small amount of aluminum powder during the mixing process, the building material can obtain a pore structure. Finely distributed aluminum in the mixture can react in an alkaline medium to form hydrogen gas, which can slowly foam the feed mixture. The pore structure may remain in the product even after the actual hydrothermal curing process and may substantially result in the properties of the final product.

In some embodiments, the production process may be broken down into one or more of the following actions:

1. grinding silica sand and preparing recycled slurry

2. Mixing and pouring aerated concrete slurry

3. Expanding, setting and cutting rough blocks or blocks

4. Curing uncut blocks under hydrothermal conditions

5. Packaging and storing the finished product

After the aerated concrete compounds are mixed and poured into steel molds, many complex chemical reactions can occur between the setting and hydrothermal curing stages. Hydration of the quicklime may begin when water is added during the mixing stage. Because this is an exothermic reaction, the aerated concrete compounds can heat up and accelerate the hydration reaction of the cement phase. Thus, during the expansion caused by hydrogen formation, continuous hardening of the aerated concrete compound may occur. In order to obtain a uniform pore structure, the gas development can be adjusted to the viscosity profile of the expanding aerated concrete compound. If this cannot be achieved, structural damage, so-called expansion cracks, may occur during expansion, which may not be corrected later in the production process. After a setting time of several hours, the uncut block can be cut into the appropriate strata by tensioned wires. All waste generated during the cutting process can be recycled in the composition so that there is no waste during the production process.

The recyclability problem is most important for the future. On the one hand, europe requires a reduction of waste, which is accompanied by an increase in the closure of landfills and the need for more recycling. On the other hand, the increasing demand for environmental protection, such as minimum thresholds and guidelines in alternative building material regulation drafts within the framework of general regulations on ground water/alternative building material/soil conservation, makes building material recovery on the market more difficult, at least in some cases. The leaching behaviour with respect to sulphate may be caused by a sulphate concentration in the eluate of between 900mg/l and 1,650 mg/l. According to the alternative building material legislation, the threshold value in the eluate for mineral-based alternative building materials is 250mg/l sulphate. The omission of sulphate carrier and cement in the production of aerated concrete can significantly reduce the above sulphate concentration in the eluate and can allow the aerated concrete construction waste to be used as a mineral-based alternative construction material.

In some embodiments, the use of a non-cement based binder according to the present disclosure may eliminate this disadvantage and may also have a very low calcium content. Other typical technical attributes may not be affected.

Precast concrete

Precast concrete parts or concrete elements are parts made of concrete, reinforced concrete or prestressed concrete, which are industrially precast in a factory and then placed in their final position, usually using a crane. Precast concrete members and reinforced concrete members are widely used and implemented in various construction techniques. The production of prefabricated components for open piping may be used in some embodiments of the present disclosure.

Fire protection

Plaster finishes for concrete and reinforced concrete components are listed in DIN 4102(Reaction to Fire of building materials and building elements). Mortars which are technically suitable as fire protection are vermiculite and perlite insulation mortars and also mortars according to DIN 18550, part 2.

In some embodiments, the spray mix may be provided as a dry mortar-mineral fiber mix, such as glass wool, rock wool, or mineral wool, having a hydraulic binder and mixed with water immediately prior to application. The technical features regarding fire protection may be the same as the sprayed asbestos.

The use of non-cement based binders in plaster facing may further improve fire resistance, as non-cement based binders may have more favourable expansion behaviour and may show lower shrinkage at high temperatures.

In some embodiments of the present disclosure, conventional mixers may not be used to produce the binder mixture. In some embodiments, inorganic materials that can be compacted or enclosed in a mold can be obtained by preparing a premix using a so-called kneader or continuous mixer, followed by mixing the aggregates using an intensive mixer or planetary mixer. And can produce the desired product after mechanical compression.

Table 4 provided below shows the application areas where mixing and application techniques can result in adhesive mixtures according to embodiments of the present disclosure.

TABLE 4

In some embodiments of the present disclosure, a method for producing a moldable concrete compound is provided. The method may include one or more of the following acts:

the method may include providing a binder mixture comprising one or more of 4 to 45% by weight volcanic rock, 0 to 40% by weight latent hydraulic material, and 10 to 45% by weight alkaline component. In one example, the alkaline component or base may be selected from and/or may include: sodium silicate, alkali hydroxide, alkali carbonate, and mixtures thereof. In some embodiments, Sulfate (SO)₄ ^2-) May be included in the binder mixture as a contaminant and is included in an amount of less than 1% by weight. In addition, calcium is contained in the binder mixture in the form of calcium oxide (CaO) in an amount of not more than 5% by weight. The process may also include producing a premix of the binder mixture with a kneader or continuous mixer. In some embodiments, the method may further comprise mixing the mixture using an intensive mixer or a planetary mixerThe pre-mix is mixed with 20% to 90% by weight aggregate to produce a moldable concrete compound. In some embodiments, this may be performed for a period of 1 minute to 5 minutes. In one embodiment, this may be done for a period of about 2 minutes.

The method may further comprise compressing the moldable concrete compound by compression or shaking to form pipes, precast concrete members, railroad connections, concrete blocks, shaped paving stones, pavement slabs, and the like.

In some embodiments of the present disclosure, a method for producing a moldable concrete compound is provided. The method may include one or more of the embodiments shown below.

In some embodiments, the method may include providing a binder mixture comprising one or more of 4% to 45% (weight percent) volcanic rock, 0% to 40% (weight percent) latent hydraulic material, and 10% to 45% (weight percent) alkaline component. In some embodiments, the alkaline component may be selected from and/or may include: sodium silicate, alkali hydroxide, alkali carbonate, and mixtures thereof. In one example, the adhesive mixture may comprise 20% to 90% (weight percent) aggregates. In some embodiments, Sulfate (SO)₄ ^2-) May be included in the binder mixture in the form of contaminants and at a level of less than 1% (by weight). In addition, the binder mixture may contain calcium in the form of calcium oxide (CaO) in an amount of not more than 5% by weight. The method may further comprise producing the dry mixture with a dry mixer. The method may further include mixing the produced dry mixture with water using an intensive mixer or a planetary mixer to produce the moldable concrete compound.

In some embodiments of the present disclosure, methods for preparing sprayable concrete compounds may be provided. The method may include one or more of the embodiments shown below.

In some embodiments, the method may include providing a binder mixture including from 4% to 45% (by weight) volcanic rock, from 0% to40% by weight of latent hydraulic hardening material, 10% to 45% by weight of one or more of alkaline components. In some embodiments, the alkaline component may be selected from and/or may include: sodium silicate, alkali hydroxide, alkali carbonate, and mixtures thereof. In some embodiments, the adhesive mixture may comprise 20% to 90% (weight percent) aggregates. In some embodiments, Sulfate (SO)₄ ^2-) May be included in the binder mixture in the form of contaminants and at a level of less than 1% (by weight). Calcium may be included in the binder mixture in the form of calcium oxide (CaO) in an amount of no more than 5% by weight. The method may further comprise producing the dry mixture with a dry mixer. In some embodiments, the method may further comprise mixing the dry mixture with water in a spray gun for the production and immediate application of the sprayable concrete compound.

In some embodiments, the adhesive mixture may be prepared for different application areas, including, for example, those listed in table 4 above. Examples 1-5 provided below may illustrate one or more embodiments of the present disclosure.

Example 1

In a mixing and kneading machine, with an extrusion screw, 1 part of finely ground volcanic rock (for example with a blaine value of 3,500), 0.15 part of fly ash and 0.8 part of sodium silicate can be combined and mixed energetically until a homogeneous, pourable paste is obtained.

The paste can be mixed with 4 parts of basalt and sand in an intensive mixer (or planetary mixer) for about 2 minutes. This makes it possible to obtain a wet, cement-free concrete which is suitable as a surface concrete in the production of concrete blocks.

The sulfate content of the mixture may be 0.16% by weight and the calcium oxide content may be 0.8% by weight.

Compression of such a mixture may be achieved by compression and shaking, for example in a briquetting machine.

The resulting products can be distinguished by significantly higher acid resistance, more favorable mechanical strength properties and significantly more intense color impression.

When other aggregate mixtures are used, such as gravel and sand, concrete pipes or specific precast concrete members can also be produced, depending on the particular particle size distribution curve. Other product variations can be achieved by controlling the moisture content and adapting the application technique (e.g. pouring, centrifuging, etc.).

Example 2

In the intensive mixer, 0.2 parts of granulated slag, 1 part of finely ground volcanic rock and 3 parts of sand may be mixed. The dry mixture can be placed in a bag.

At the construction site, 1 part of the mixture produced in this way can be mixed in a road mixture with 0.7 parts of sodium silicate and brought to the desired consistency.

The sulfate content of the mixture may be 0.19% by weight and the calcium oxide content may be 0.57% by weight.

The non-cement-based masonry and mortar obtained in this way can be applied to the surface to be coated in different ways (e.g. by conventional plastering, spraying, etc.).

Example 3

In a dry mixer, a dry mixture may be prepared consisting of 1 part pozzolan (e.g., a blaine value greater than 3,500), 0.4 part fly ash, 1 part perlite, and 0.7 part powdered sodium silicate.

The dry mixture can be moistened with water by intensive mixing with high shear forces, poured into a mould and compressed.

The wet mixture may have a sulphate content of 0.32% by weight and a calcium oxide content of 1.8% by weight.

In one practice based on the above examples, samples were obtained after the hardening phase, which did not show cracks or visible fissures after being subjected to a long flame, nor did they show reduced mechanical strength properties. And (6) testing. There was no significant damage after freezing temperatures.

Example 4

In a dry mixer, a dry mixture may be prepared consisting of 1 part pozzolan (e.g., having a blaine value greater than 3,500), 0.4 part granulated slag, 1 part perlite and 0.7 part powdered sodium silicate.

The dry mixture may be continuously supplied to the spray gun and may be combined with water to produce sprayable concrete. The spray technique using heat and fire resistant non-cement based compounds allows to seal or coat pipe and cable penetration holes, heat sensitive building materials and surfaces without difficulty.

The sprayable concrete may have a sulphate content of 0.31% by weight and a calcium oxide content of 1.29% by weight.

Example 5

For the production of aerated concrete, 16.2 parts of volcanic rock, 3.35 parts of fly ash, 23 parts of silica sand may be intensively premixed in a commercially available mixer. The dry mixture may be added 33 parts sodium silicate at 38 ℃ under strong shear force and may be further mixed with 0.43 parts aluminum paste in the same mixer.

The binder mixture may be poured into a teflon mold and heated in the mold for 120 minutes to 80 ℃. The mixture can harden while increasing in volume, but still be cut. For curing, the mold may be placed in a curing chamber and may be held therein at 180 ℃ for 30 minutes. Alternatively, an autoclave may be used for curing at 120 ℃.

It is possible to obtain shaped bodies having optical properties comparable to those of aerated concrete obtained according to typical methods. Unlike typical aerated concrete, the material may be acid resistant, with a sulphate content of 0.21% by weight and a calcium oxide content of 0.6% by weight. In one embodiment, the resulting building material may have very low sulfate and calcium content.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

Having described the disclosure of the present application in detail and by reference to embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the disclosure defined in the appended claims.