Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
  • C04B20/02—Treatment
  • C04B20/026—Comminuting, e.g. by grinding or breaking; Defibrillating fibres other than asbestos
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
  • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
  • B02C23/00—Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group
  • B02C23/08—Separating or sorting of material, associated with crushing or disintegrating
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
  • C04B28/04—Portland cements
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
  • C04B38/08—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding porous substances
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/40—Porous or lightweight materials
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/60—Flooring materials
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

• the present invention relates to a building material for producing lightweight concrete and thermally insulating for use both as ready-mix concrete or in the manufacture of prefabricated parts.
• the present invention relates to aggregates obtained from cellular concrete, having particle size characteristics for agglomerating them with a hydraulic binder (lime, activated clays, cements of all types in accordance with the EN 197-1 standard, etc.); preferably, the cement-type binders will be used.
• a hydraulic binder limestone, activated clays, cements of all types in accordance with the EN 197-1 standard, etc.
• Cellular concrete designed in 1924 by J.A. Erikson, is made primarily from sand, portland cement, lime and water, which gives it the characteristics of stone: solid, hard, dimensionally stable, rot-proof and non-flammable. Its honeycomb structure made up of air micro-cells gives it its properties of reduced density and thermal and acoustic insulation. It is essentially distributed in block form with multiple dimensional characteristics to suit most masonry building systems. Its method of manufacture does not reject any substance likely to pollute the water or the grounds. In the atmosphere, the only gas released is water vapor. However, the manufacturing process generates cellular concrete waste whose quantity is estimated at about 3% of the total volume manufactured. This waste comes from the thickness of material at the bottom of the mold, unusable for the manufacture of blocks, and scrap of finished products. This cellular concrete waste is partially recycled in the manufacturing process or used as absorbent or insulating product. The rest is stored in landfill.
• the manufacture of light insulating concrete is traditionally made from aggregates of natural minerals (pozzolana), natural minerals heated (perlite, exfoliated vermiculite or expanded clay beads) or polystyrene beads.
• pozzolana natural minerals
• natural minerals heated perlite, exfoliated vermiculite or expanded clay beads
• polystyrene beads The use of these materials leads to environmental impacts such as the exploitation of natural resources or the emission of greenhouse gases.
• Cellular concrete typically has a density of between 350 kg / m 3 and 550 kg / m 3 .
• the density of the aggregates produced from a given cellular concrete remains unchanged as long as the size of the granulate remains greater than about 1-2 mm.
• the size of the micro-cells of the cellular concrete ranging from a few tenths of a millimeter to about two millimeters in diameter, a size too small aggregates, that is to say less than 2 mm, virtually eliminate the presence of these micro-cells in the material, which would significantly reduce or even negate its reduced density and thermal and acoustic insulation properties expected in lightweight and insulating concrete.
• the aggregates obtained must also be uniform in size and must have a rounded shape that conditions the placement properties of the future concrete.
• aggregates with sharp and brittle edges would produce a new large quantity of fine particles during handling, transport and mixing with cement and water, which should be extracted before use or which would degrade the quality of the concrete. forming during the preparation of concrete.
• the invention relates to aggregates obtained from cellular concrete waste which are particularly suitable for application in concrete for the manufacture of walls, slabs or any other form obtained during the placement of concrete ready for use. employment or prefabricated.
• an object of the invention lies in the use of cellular concrete granules calibrated between 2 and 25 mm and bulk density in the dry state ranging from 200 to 600 kg / m 3 , allowing their agglomeration with a binder. for the manufacture of light and insulating concrete.
• Another object of the invention is the use of the aforementioned aggregates for the manufacture of slabs, screeds, slab walls or prefabricated parts, such as, for example, blocks, horizontal or vertical chaining blocks, beams, premurs, ....
• the aggregates preferably have the following properties, taken alone or in combination: their bulk density in the dry state varies from 350 to 550 kg / m 3 ; they are calibrated from 4 to 12 mm.
• said binder can be chosen from any hydraulic binder such as lime, activated clays, cements of all types in accordance with the EN 197-1 standard, etc. ; cement-type binders and especially Portland cements are preferred.
• the invention also relates to a method of manufacturing aggregates for use in concrete, obtained by crushing cellular concrete waste.
• Another subject of the invention is a process for manufacturing cellular concrete aggregates with a size of at least 2 mm, comprising the following steps:
• crushed blocks are screened dry in order to remove fines and aggregates with a size of less than 2 mm, and
• the aggregates with a size of at least 2 mm are recovered.
• granulates having a size of at most 25 mm are manufactured.
• the screening operation also makes it possible to eliminate aggregates with a size greater than 25 mm.
• the cellular concrete blocks treated by the process of the invention have very variable dimensions and it may be advantageous to provide, before engaging the above steps, one or more series comprising a preconcassage step and a screening step , to obtain blocks of sizes between 2 and 8 mm, which are then treated as described above.
• Figure 1 is a photo of blocks of cellular concrete waste before crushing. The bar represents 15 cm.
• FIG. 2 represents particle size curves illustrating the% by weight of material passing according to the size of the granules, after crushing, obtained by two different types of crushers, an impact crusher (A) and a jaw crusher (B).
• FIG 3 shows photos of crushed cell concrete aggregates (jaw crushers) before screening (A) and after screening (B).
• Figure 5 is a diagram of a plant for crushing and screening of cellular concrete waste, the arrows correspond to the flow of material.
• Table 1 below shows examples of the size of cellular concrete waste from manufacturing scrap.
• the base material comes, for example, from the production drops of the cellular concrete blocks, such as the thickness of the material at the bottom of the mold, which is unusable for the manufacture of blocks, and of rejects.
• of finished products typically consist of parallelepipedic blocks whose dimensions vary from a few centimeters for the smallest to several tens of centimeters plus the largest ones.
• the apparent density of the cellular concrete waste stock is typically 200 kg / m 3 .
• the calibrated cellular concrete aggregates are obtained by successive operations of crushing of cellular concrete blocks and screening.
• the crushing is carried out by means of jaw crushers or roller mills (otherwise called rotor crushers). These crushing processes are the most efficient for treating this type of material because it limits the production of fines in comparison with the conventional method of percussion crushing, as Figure 2 demonstrates.
• Screening is advantageously carried out by means of a vibrating screen having at least two stages of grids for separating the aggregates respectively below and below the desired cut.
• the screening must be carried out without washing and the screened cellular granulate must be as wet as possible. This is why, ideally, the cellular concrete waste to be treated must be stored in a dry place protected from the rain.
• the size between the bars of each grid is preferably 2 mm greater than the minimum and maximum desired size of the aggregates.
• the upper grid of the screen will have for example a spacing between the bars of 14 mm and the bottom grid and a spacing between the bars of 6 mm.
• the screens of a crusher having a surface typically of 4 to 8 m 2 have an inclination of 30-40 ° with respect to the horizontal to allow to quickly evacuate the non-passing material and to allow 'increase the passing portion.
• Aggregates produced from aerated concrete must approach a spherical shape with no significant asperities that would break during transport and during concrete preparation.
• the average magnitudes targeted are typically as follows:
• the process according to the invention must make it possible to produce at least 40% and generally at most 70% by volume of usable granular aggregates whose average size is greater than or equal to 1 mm.
• the productivity must reach more than 100 m 3 / day (more than 15 m 3 / h).
• Figure 5 illustrates an installation for implementing the method of manufacturing aggregates.
• the references mentioned in this figure correspond to the different positions of this installation:
• raw block supply 1 feed hopper preconceller
• the screeners are jaw.
• the material resulting from the pre-crushing in the first crusher 2 is screened in the sifter 4 to recover the amount of finished product obtained during this operation and pass through the second crusher 6 only the aggregates larger than the maximum dimension of the desired break.
• Granulometry aggregates calibrated between 2 mm and 25 mm maximum (for example: 4/12 cellular concrete granules). The size of the aggregates is voluntarily limited to 25 mm. Larger aggregates would cause too much weakening of the mechanical strength of the concrete, the mechanical strength of the aggregates being much lower than that of the matrix of the hydraulic binder.
• the mixture for the manufacture of lightweight insulating concrete consists of sand, cement, aerated concrete aggregates and water.
• Each objective of technical characteristics including density corresponds to a specific formulation defining the dosage of each component.
• the mixture is made either in a concrete plant or in a concrete mixer.
• the calibrated cellular concrete aggregates can be delivered in bulk by dump truck, in "big bag” packaging or in bags.
• the material according to the invention is particularly intended for the manufacture of light insulating concrete to reduce weight compared to traditional concretes and to provide thermal and acoustic insulation. It can be used for the manufacture of slabs, screeds, slotted walls or prefabricated parts (for example: blocks, horizontal or vertical chaining blocks, beams, premurs, ).

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Food Science & Technology (AREA)
• Porous Artificial Stone Or Porous Ceramic Products (AREA)
• Processing Of Solid Wastes (AREA)
• Civil Engineering (AREA)
• Moulds, Cores, Or Mandrels (AREA)
• Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
• Environmental & Geological Engineering (AREA)

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Publications (1)

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• 2010
  • 2010-07-21 FR FR1003056A patent/FR2962999B1/fr not_active Expired - Fee Related
• 2011
  • 2011-07-21 MX MX2013000814A patent/MX353591B/es active IP Right Grant
  • 2011-07-21 WO PCT/FR2011/051763 patent/WO2012010804A1/fr not_active Ceased
  • 2011-07-21 US US13/811,194 patent/US9120702B2/en not_active Expired - Fee Related
  • 2011-07-21 PH PH1/2013/500137A patent/PH12013500137A1/en unknown
  • 2011-07-21 EP EP11752266.4A patent/EP2595938A1/de not_active Withdrawn
• 2013
  • 2013-01-18 GT GT201300022A patent/GT201300022A/es unknown
  • 2013-01-18 DO DO2013000020A patent/DOP2013000020A/es unknown
  • 2013-01-18 NI NI201300009A patent/NI201300009A/es unknown
  • 2013-01-21 CO CO13010228A patent/CO6680614A2/es unknown
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