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
  • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
  • C04B40/06—Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
  • C04B40/0608—Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
• • 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
  • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B18/04—Waste materials; Refuse
  • C04B18/18—Waste materials; Refuse organic
  • C04B18/20—Waste materials; Refuse organic from macromolecular compounds
• • 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
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/0075—Uses not provided for elsewhere in C04B2111/00 for road construction
• • 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
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00767—Uses not provided for elsewhere in C04B2111/00 for waste stabilisation purposes
• • 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 invention relates to concrete doped with glass fiber reinforced thermoset plastic waste, process for preparing the same and a lightweight dry concrete premix usable in said process.
• Glass fiber reinforced plastic composites have specific role among thermoset plastics.
• Thermoset SMC products (Sheet molding Compound) comprising glass fiber, in particular SMC products based on unsaturated polyester, further BMC products (Bulk molding Compound) and FRP products (Fiber-Reinforced Plastic) are widely used both outdoor and in-door, since they keep their excellent features for a long time.
• BMC products Bulk molding Compound
• FRP products Fiber-Reinforced Plastic
• Patent Document HU222303 proposes the use of fibrous aggregates or fibrous fillers.
• additives are added to ground concreting mixture to improve its static and dynamic parameters, wherein as additives, mineral fibers, glass fibers, cellulose fibers, steel fibers, carbon fibers, plastic fibers and in particular coated glass fibers are mentioned.
• Glass fiber is used as a separate material, i.e. its embedding into any other material is not mentioned. Furthermore the treatment of the fibrous material with a surface-active agent is not disclosed.
• International Publication Document WO2004039746 (Al) glass fiber aggregate is used for fabricating footpath coverings.
• Finely ground powder of fiberglass and a component consisting of flexible glass wool are used in separate steps of the process.
• the cement concrete product to be prepared this way is formed layer by layer in a mold made of low density polyethylene.
• the end product practically has two layers.
• the glass fiber and the glass wool are present as separate components in the layers.
• the glass fibers are not combined with other materials, like a thermoset.
• Application JP 10-053451 provides technical solution for the use of industrial waste dusts of any origin, containing glass fiber, by adding them to cement and water.
• this application refers to recycling of synthetic wood i.e. expanded urethane.
• the end product includes industrial dust, glass fiber, cement, water and ground synthetic wood, which mixture has a porous structure after setting and thus it is useful for draining groundwater.
• a special field of use is water drainage of golf-courses.
• the documents belonging to the prior art do not disclose products comprising glass fiber and plastic waste where the glass fiber was originally included in the plastic as a result of a previous preparation process.
• Other documents do not deal with the influence of the size of the ground particles comprising glass fiber fragments on the strength of the concrete product. Accordingly, the relationship between the main binding component, i.e. cement powder, and the particle size of the ground material was not examined, furthermore no reference to this relationship can be found in these documents.
• these documents do not provide exact technical solution for the environmentally friendly recycling of SMC, BMC and FRP thermoset products comprising glass fiber.
• Another object of the present invention was to provide solution for the safe disposal of the increasingly accumulating amounts of non environmentally friendly thermoset plastic waste.
• the present invention we surpassed this aim and created the hydraulic mixture of materials compounded as proposed, which shows improved features, i.e. higher tensile strength and compressive strength, bending strength and impact strength, further higher abrasive hardness and freezing resistance, and does not crack while setting.
• the process according to the present invention fits well to the otherwise known concrete preparing processes and mechanical bulk production technologies as well as instruments used for concrete mixing.
• the present invention relates to a process for preparing doped concrete by embedding glass fiber reinforced ground thermoset plastic waste in hydraulic concrete mortar prepared with cement.
• the glass fiber reinforced thermoset plastic waste is separated from foreign materials, then ground optionally in several steps to form ground plastic waste having particle size one order of magnitude larger than the particle size of the cement, then a) cement, graded gravel, sand, water, said glass fiber reinforced ground thermoset plastic waste and optionally other additives commonly used in the preparation of concrete mortar are mixed applying wet technology, or
• cement, gravel and sand, said glass fiber reinforced ground thermoset plastic waste and optionally other dry additives commonly used in the preparation of concrete mortar are mixed and homogenized applying dry technology to form a dry premix, to which water and optionally other dry and/or wet additives commonly used in the preparation of concrete mortar are added with continuous agitating, before use, and after carrying out process step a) or b) the final consistency of the concrete mortar is optionally adjusted with continuous agitating and the resultant concrete mortar is poured and allowed to set.
• the invention further relates to a lightweight dry concrete premix containing glass fiber reinforced ground thermoset plastic waste, cement and optionally other dry additives commonly used in the preparation of concrete, wherein the particle size of the ground plastic waste is one order of magnitude higher than the particle size of the Portland cement.
• the lightweight dry concrete premix is packed in unit portions.
• the invention further relates to a process for preparing doped concrete by embedding glass fiber reinforced ground thermoset plastic waste in hydraulic concrete mortar prepared with cement, where in the process said lightweight dry concrete premix is mixed with graded gravel, sand, water and optionally other dry additives commonly used in the preparation of concrete mortar, then the final consistency of the concrete mortar is adjusted with continuous agitating and the resultant concrete mortar is poured and allowed to set.
• the concrete mortar prepared by any of the above processes is placed with pouring, self-spreading technology or with framework technology, in step-by-step or continuous process or by preparing discrete elements.
• the invention further relates to a concrete product prepared by any of the above processes, containing the following components expressed in % by volume of the concrete:
• the average particle size of the glass fiber reinforced ground thermoset plastic waste is 300 ⁇ or more.
• the , average particle size of the glass fiber reinforced ground thermoset plastic waste is between 500 ⁇ and 3 mm.
• glass fiber reinforced thermoset waste glass fiber reinforced thermoset SMC and/or BMC and/or FRP waste comprising more than 10 % by volume glass fiber is used.
• the other additives are materials advantageously influencing the preparation process or the features of the end product.
• they are colorants, materials influencing the setting rate, antimolding agents, freezing point lowering agents and the like.
• the concrete product is a concrete building element or a discrete element, which is preferably a pre-product, a cover element or a mobil element.
• the cement is preferably Portland cement.
• Building elements prepared from this high-strength concrete can advantageously be used in building construction and civil engineering and also for preparing discrete elements, for example structures. Moreover large amounts of high-strength concrete products are consumed by road and railway construction. Concrete can be prepared in small amounts or in large scale, further it can be job-mixed or machine-made and produced by an automated process. Concrete transporting is technically solved, concrete placing technologies are available.
• the present invention relates to the preparation of concrete doped with glass fiber reinforced thermoset waste which is prepared by combining hydraulic concrete with glass fiber reinforced ground thermoset plastic waste.
• the process according to the invention is disclosed below in detail.
• glass fiber reinforced thermoset plastic is prepared for grinding, foreign materials, such as metals are separated, then it is ground expediently in multiple steps, that is, coarse grinding and fine grinding is carried out.
• the average particle size of the ground material is adjusted to one order of magnitude larger than the average particle size of the cement to be incorporated. In view of the fact that the average particle size of the Portland cement is about 30 ⁇ , grinding of the plastic waste is continued until its particles reach a size equal to or larger than 300 ⁇ .
• the concrete mortar taking up the ground plastic is prepared and homogenized, where the components of the concrete mortar are: Portland cement, filtered purified water, river gravel and sand.
• the ground component prepared in the first step is added to the concrete mortar obtained above. Finally, the other additives are added, then a final homogenization is carried out and the required consistence is adjusted, then the concrete is poured and allowed to set.
• composition of the concrete prepared according to the foregoing is preferably as follows: 1 1 to 16 % by volume cement, 1 to 16 % by volume ground thermoset plastic, 0 to 2 % by volume other additives, 3 to 10 % by volume purified filtered water and the rest are gravel and sand in ratio 1 :1.
• a premix is prepared from all of the dry components, i.e. from cement powder, dry gravel, dry sand, ground thermoset plastic, expediently by machinery, in an automatic mixing plant with proportionate dosing control, and the wet components are added with continuous agitating, during or after transporting to the place of concreting.
• the invention can be implemented by dry premixing the ground thermoset, the cement powder and optionally the other additives in suitable ratio to obtain lightweight dry concrete premix, which is then portioned out and packed in the form of unit portions, i.e. pre-packed.
• the concrete mortar can be placed by pouring, self- spreading or cradling technology, in step-by-step or continuous process or by preparing discrete elements, for example pre-products, cover elements or mobil elements.
• thermoset plastics otherwise harmful to the environment. Having embedded into concrete commonly used in building industry they do not exert harmful effect on the environment. On the effect of pressure and heat used in the preparation of thermoset the structure of the glass fiber surface decomposes. Activation of the surface is also promoted by the chemical milieu inside the resin. During grinding this surface considerably increases. Glass fibers take part in the hydraulic bonding with relative large activated surface. This explains the outstanding mechanical properties of the doped concrete prepared by the process according to the present invention.
• Reinforced concrete basement subbase is prepared via large scale continuous concrete production.
• the concrete is transported to the place of use in transit mixer with pear-shaped drum, incorporated using mechanical pump on 25°C, then compacted with vibrator rod and the surface is spaded using a finishing disc.
• concrete subbase having structural thickness 55 cm (without blanket insulation) is formed.
• composition of concrete is as follows:
• thermoset glass fiber content : at least 17%) 7 % by volume
• the above composition is cast in place. According to our experience the glass fiber reinforced ground thermoset used is fully covered by the spaded finish of concrete. The embedded glass fibers take a substantial part in the hydraulic bond. The hardened surface is event, crack-free and can be coated without a leveling course. Hygroscopicity of the final concrete subbase was not experienced. Mechanical properties of standard cast-in-place cubes were examined in mechanical test laboratory, where all the received data surpassed the data measured for the references (see Table after the Examples).
• Public road bed is prepared by continuous spreading in standard breadth and average depth of 50 cm. The conditions of preparation and pouring were identical with those described in Example 1.
• composition of concrete is as follows:
• thermoset containing mixed glass fiber
• one half is from 24 to 30 mm and the other half is kule gravel with sizes up to 63 mm 50 % by volume of the rest and
• the concrete bed prepared this way takes up the glass fiber reinforced plastic waste otherwise qualified as harmful to the environment. After hardening the concrete has a closed surface, the embedded ground plastic is not released. Owing to its physical properties, i.e. good waterproofhess, no dissolution was experienced.
• the glass fiber takes an active part in hydraulic bond and shows characteristics of pure silicate.
• the mechanical strength of the concrete prepared according to this process is better than those of the concrete bed materials of control compositions (see in the Table).
• Fencepost elements are prepared from pre-packed dry lightweight concrete premix.
• the size of the post at base is 20 x 20 cm and at cap is 10 x 10 cm, its length is 3 m.
• the fence element is equipped with four reinforcing iron accessories of 10 cm having extending galvanized lugs for fixing wire mesh.
• the concrete is mixed in place and a gauge is used for pouring.
• the concrete may be agitated manually or mobil concrete mixer can be used.
• the proposed composition is as follows:
• thermoset thermoset
• Colored outdoor going elements, flags are prepared in size 40 x 40 x 8 cm using gauges, by the home-made process outlined above.
• the proposed composition is as follows: ⁇ pre-packed lightweight dry concrete premix containing
• thermoset thermoset, and sand 45 % by volume
• the table below shows the characteristic data of the samples prepared from the concrete products of the present invention, which were determined by the standard methods described above, as compared to data determined under similar conditions, of concrete products comprising glass fiber reinforced plastic waste representing the closest prior art.
• a great advantage of the present invention is that it contributes to the removal of plastic waste by using it in concrete prepared for the building industry, thereby decreasing harmful effect of said waste on the environment.
• a further unexpected effect of the present invention is that the characteristics of the concrete products, such as tensile strength, bending strength, impact strength, abrasive hardness, compressive strength and resistance to shear and extreme conditions, like fire- resistance and frost-resistance, and crack resistance are highly improved.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Structural Engineering (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Civil Engineering (AREA)
• Environmental & Geological Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Processing Of Solid Wastes (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Reinforced Plastic Materials (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (2)

Publications (1)

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• 2011
  • 2011-11-02 HU HU1100606A patent/HUP1100606A2/hu active IP Right Revival
• 2012
  • 2012-10-31 EP EP12815754.2A patent/EP2773597A2/de not_active Withdrawn
  • 2012-10-31 WO PCT/HU2012/000118 patent/WO2013064849A2/en not_active Ceased

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