EP4304823A1 - Procédé de production de mélanges de béton légers à l'aide d'agrégats légers - Google Patents

Procédé de production de mélanges de béton légers à l'aide d'agrégats légers

Info

Publication number
EP4304823A1
EP4304823A1 EP21847981.4A EP21847981A EP4304823A1 EP 4304823 A1 EP4304823 A1 EP 4304823A1 EP 21847981 A EP21847981 A EP 21847981A EP 4304823 A1 EP4304823 A1 EP 4304823A1
Authority
EP
European Patent Office
Prior art keywords
lightweight
mixture
lightweight concrete
weight
mixing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21847981.4A
Other languages
German (de)
English (en)
Inventor
Thomas Sievers
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
B Ton Ip GmbH
Original Assignee
B Ton Ip GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by B Ton Ip GmbH filed Critical B Ton Ip GmbH
Publication of EP4304823A1 publication Critical patent/EP4304823A1/fr
Pending legal-status Critical Current

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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
    • 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
    • C04B28/006—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 mineral polymers, e.g. geopolymers of the Davidovits type
    • C04B28/008—Mineral polymers other than those of the Davidovits type, e.g. from a reaction mixture containing waterglass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/08—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions using driven mechanical means affecting the mixing
    • B28C5/10—Mixing in containers not actuated to effect the mixing
    • B28C5/12—Mixing in containers not actuated to effect the mixing with stirrers sweeping through the materials, e.g. with incorporated feeding or discharging means or with oscillating stirrers
    • B28C5/1223—Mixing in containers not actuated to effect the mixing with stirrers sweeping through the materials, e.g. with incorporated feeding or discharging means or with oscillating stirrers discontinuously operating mixing devices, e.g. with consecutive containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
    • B01F35/20—Measuring; Control or regulation
    • B01F35/22—Control or regulation
    • B01F35/2201—Control or regulation characterised by the type of control technique used
    • B01F35/2209—Controlling the mixing process as a whole, i.e. involving a complete monitoring and controlling of the mixing process during the whole mixing cycle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
    • B01F35/20—Measuring; Control or regulation
    • B01F35/22—Control or regulation
    • B01F35/221—Control or regulation of operational parameters, e.g. level of material in the mixer, temperature or pressure
    • B01F35/2214—Speed during the operation
    • B01F35/22142—Speed of the mixing device during the operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/003—Methods for mixing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/08—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions using driven mechanical means affecting the mixing
    • B28C5/0875—Mixing in separate stages involving different containers for each stage
    • 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
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
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    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • 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
    • C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • C04B18/08—Flue dust, i.e. fly ash
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    • 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
    • C04B20/10—Coating or impregnating
    • C04B20/1018—Coating or impregnating with organic 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
    • 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
    • C04B28/006—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 mineral polymers, e.g. geopolymers of the Davidovits type
    • 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
    • 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
    • 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
    • C04B28/08—Slag 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
    • 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
    • C04B28/08—Slag cements
    • C04B28/082—Steelmaking slags; Converter slags
    • 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
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • C04B40/0032—Controlling the process of mixing, e.g. adding ingredients in a quantity depending on a measured or desired value
    • 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
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • C04B40/0039—Premixtures of ingredients
    • C04B40/0042—Powdery mixtures
    • 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
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • C04B40/0057—Energetic mixing
    • 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
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/30—Water reducers, plasticisers, air-entrainers, flow improvers
    • C04B2103/304—Air-entrainers
    • 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
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • 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
    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density

Definitions

  • the method according to the invention for the production of lightweight concrete mixtures using lightweight aggregates comprises an at least two-stage mixing process, in which first a suspension mixture containing the binder composition is prepared with a cement or a geopolymer and water with rapid stirring and the suspension mixture is then slowly stirred with the lightweight aggregates, among other things becomes.
  • the invention also encompasses lightweight concrete mixtures and lightweight concretes produced in this way.
  • Concrete has a defined density from 2,000 kg/m 3 to 2,600 kg/m 3 measured as dry bulk density with a minimum compressive strength of 8 N/mm 2 .
  • Lightweight concrete is defined as concrete with a dry bulk density below 2,000 kg/m 3 .
  • the low densities in lightweight concrete are achieved, for example, by adding lightweight aggregates.
  • Lightweight aggregates for example, have bulk densities of 40 to 1200 kg/m 3 .
  • Lightweight concrete is used to manufacture building products.
  • lightweight concrete is a building material before it is shaped and, after at least partial curing, it is a component.
  • Components are manufactured to be permanently installed in structural systems. Construction products also include systems made of building materials and components that are manufactured to be connected to the ground, such as buildings. Buildings can be prefabricated houses, prefabricated garages and silos or so-called "temporary structures" that are suitable for repeated and temporary erection and dismantling at different locations.
  • Typical components are lightweight concrete wall elements or lightweight concrete ceiling elements or lightweight concrete bricks.
  • Lightweight concrete is suitable for exterior and interior walls, from the basement to the roof, for residential buildings as well as for agricultural, public or industrial buildings and bridges. Lightweight panels can also be made from lightweight concrete for insulation purposes or fire protection, etc., the compressive strength of which can also be lower.
  • the component made of lightweight concrete should have a high ratio of compressive strength to dry bulk density.
  • the dimensionless so-called A number results from a calculated relationship between the compressive strength and the dry bulk density.
  • the A number is described by Siegfried G. Zürn in "Influence of the sand minerals on the formation of calcium silicate hydrates (CSH phases), the structure and the mechanical properties of aerated concrete products", logos-Verlag, Berlin, 1997. It represents the relative Compressive strength.The larger the A number, the better the level of compressive strength.The A number is calculated as follows:
  • a number compressive strength (in N/mm 2 ): [dry density (kg/dm 3 ) 2 0.016].
  • the lower weight of the component or the building material during transport simplifies and reduces transport to the construction site, reduces CO2 emissions through additional loading and enables fast and precise work.
  • Short construction times can be achieved particularly with prefabricated elements made of lightweight concrete - they can be produced in the factory with integrated supply lines, doors and windows as well as finished surfaces.
  • the light elements can also be transported on construction sites in difficult positions.
  • components For components, the higher the weight, the higher the sound reduction index. Despite its lower weight, components made of lightweight concrete have a high level of sound absorption, i.e. good soundproofing properties.
  • the water absorption of lightweight aggregates i.e. the absorption behavior
  • lightweight aggregates with low bulk density and grain strength for use in building materials such as wall and ceiling elements and bricks.
  • Such a use has so far failed, in particular due to the high absorbency of these lightweight aggregates, which means that when the lightweight aggregates are mixed with cement at the same time, water is extracted from the cement.
  • a low grain strength is problematic because, when mixed in standard industrial concrete mixers, it causes the lightweight aggregates to be crushed during the mixing process and thus achieve a larger surface area, with the result that the water and binding agent requirements continue to increase and thus, in addition to other unfavorable properties such as greater tendency to shrink and risk of cracking, and the density of the end products also increases unintentionally.
  • the invention is based on the object of making available a lightweight concrete for the production of building products which can also be produced using lightweight aggregates with low grain strength and bulk density, the lightweight concrete having dry bulk densities (measured according to DIN EN 12390-7 in a heating cabinet at 105 °C) from 200 kg/m 3 to 1999 kg/m 3 and compressive strengths from 0.5 N/mm 2 to greater than 100 N/mm 2 .
  • Components made of lightweight concrete should have low dry bulk densities, improved thermal insulation values and very good sound insulation values as well as, due to the type of production, a high final strength in relation to the density with an A number greater than 500.
  • a binder should be used in the production of lightweight concrete, such as a geopolymer or a cement with a low clinker content and a high proportion of substitute materials such as ground granulated blast furnace slag.
  • the invention also relates to a lightweight concrete mixture and the lightweight concrete hardened in a mold.
  • the method for producing a lightweight concrete mix includes at least the following steps:
  • the binder composition comprising at least cement or geopolymers as binder, the water preferably being initially introduced and the binder composition being added with mixing, and
  • the weight ratio of water to binder composition in the suspension mixture being from 1:5 to 1:1, in particular from 1:2 to 2:3; wherein the binder constitutes at least 40% by weight of the binder composition, preferably at least 50% by weight; wherein the binder is added as a powdered solid; and
  • Step A and step B take place with mixing with different inputs of mixing energy, namely with a fast-running stirring tool (A) and with a slow-running stirring tool (B).
  • Step A is preferably carried out, for example, for 60 to 360 seconds, in particular 120 to 240 seconds. (from the addition of the cement/geopolymer), carried out and independently of this step B for at least 120 seconds, in particular 180 to 360 (from the addition of the suspension mixture).
  • the “mixing water” is first brought into contact with the cement or geopolymer, including the other substances in the binder composition, and is “disrupted” while being mixed with a high-speed stirrer to obtain the suspension mixture before the usually absorbent lightweight aggregates are mixed with the mixing water contact. Then the lightweight aggregates are brought into contact with the suspension mixture. It was surprisingly found that the water is then better available for the water-cement reaction or geopolymer-water reaction and the lightweight aggregates no longer compete for the availability of the water. Overall, therefore, less water can be used.
  • the method according to the invention comprises at least two mixing processes:
  • the binder or binder composition is preferably added only to the suspension mixture.
  • the suspension mixture After mixing in step A, the suspension mixture has a flowability of at least F6. Preferably 22 to 40% by weight of water is added to the suspension mixture or the suspension mixture preferably contains 22 to 40% by weight of water.
  • the binder composition for preparing the suspension mixture may contain:
  • Cement as a binder and rice husk fly ash prepared by grinding as a binder additive, in particular 10 to 60% by weight, based on the binder composition.
  • the binder composition can be a geopolymer comprising 2 to 25% by weight of alkali metal hydroxides and/or alkali metal silicates and 75 to 98% by weight of ground granulated blastfurnace slag or 2 to 20% by weight of alkali metal hydroxides and/or alkali silicates and 60 to 78% by weight of ground granulated blastfurnace slag and 20 up to 38% by weight fly ash.
  • fillers in the form of rock flour and/or aggregate 0-2 mm are added to produce the suspension mixture and then the mixing with the high-speed stirring tool is preferably temporarily carried out with a Froude number greater than 50 and in particular greater than 100, in particular for at least 30 seconds, particularly preferably at least 60 seconds, the crushed rock preferably being added in an amount of 50 to 150 kg per m 3 lightweight concrete mixture and the aggregate 0-2 mm preferably being added in an amount of 100 to 500 kg per m 3 lightweight concrete mixture becomes.
  • the lightweight aggregates can have a grain size in the range from 0 mm to 6 mm, as grain groups in particular from 0 to 2 mm, 0 mm to 3 mm, 3 to 5 mm or 2 to 8 mm in accordance with DIN EN 13055 in each case.
  • a hydrophobing agent can be applied to the lightweight aggregates before addition of the suspension mixture; additionally or alternatively, the lightweight aggregates can be moistened with water, in particular by spraying, before addition of the suspension mixture.
  • the lightweight concrete preferably has a dry bulk density of between 250 and 1999 kg/m 3 and an A number greater than 500 independently of this.
  • the lightweight concrete mixture can be introduced into molds in stone molding machines and compacted by shaking and/or pressing in order to produce lightweight concrete in the form of lightweight concrete blocks.
  • the lightweight concrete mix has e.g. the following components (related to the total mass of the lightweight concrete mix):
  • - binder composition in the range from 10 to 90% by weight, ie for example also in the range from 25 to 85% by weight or in the range from 40 to 80% by weight;
  • Lightweight aggregates in the range from 1 to 50% by weight, ie for example also in the range from 5 to 30 or in the range from 5 to 15% by weight;
  • a lightweight concrete mixture with the additional use of aggregate, in particular aggregate 0 to 8 mm, includes the following components (related to the total mass of the lightweight concrete mixture):
  • - binder in the range from 15 to 70% by weight, ie for example also in the range from 20 to 60% by weight or in the range from 25 to 55% by weight;
  • Lightweight aggregates in the range from 3 to 40% by weight, ie for example also in the range from 5 to 20 or in the range from 1 to 15% by weight;
  • - Aggregate in the range from 5 to 65% by weight, ie for example also in the range from 20 to 60% by weight, in the range from 30 to 60% by weight or in the range from 40 to 60% by weight;
  • the lightweight aggregates can first be brought into contact with a proportion of the suspension mixture as part of step B, with the lightweight aggregates preferably being initially introduced and then the further proportions of lightweight aggregates and suspension mixture being added together or sequentially in one or more steps, with mixing according to step B.
  • the binder composition consists of the binder and, if necessary, the binder additive.
  • the binder and, as a rule, also the binder additive is present as a powdered solid.
  • Binders for the method according to the invention are cement and geopolymers.
  • cement or “cements” are inorganic, finely ground substances which, after being mixed with water, solidify and harden (hydraulic setting) as a result of chemical reactions with the mixing water.
  • cement is mainly siliceous calcium with proportions of aluminum and iron compounds, which is present as a complicated mixture of substances.
  • the raw materials used to make cement are limestone (calcium carbonate as a source of calcium oxide), clay (for silica and alumina), sand (for silica), and iron ore (ferric oxide).
  • the raw materials are ground and heated until they partially fuse together at the grain boundaries (sintering) and the so-called cement clinker is formed. This is cooled and ground into the end product cement.
  • Geopolymers are two-component systems consisting of a reactive solid containing silicon and aluminum oxides and a basic activating solution of alkali hydroxides or silicates in water. Geopolymers can also be produced from ground granulated granulated blast furnace slag and/or fly ash or a mixture thereof, these being alkaline activated with alkali hydroxides and/or alkali silicates.
  • the activation solution comprises, for example, sodium, potassium and/or lithium waterglass, particularly preferably potassium waterglass.
  • Fly ash, granulated blast furnace slag, amorphous silicon dioxide such as microsilica, pozzolana (possibly together with calcium hydroxide), burnt slate, calcium oxide and magnesium oxide, ground perlite, trass and graphene are suitable as binder additives.
  • Silica fume or Microsit® can be used as amorphous silicon dioxide.
  • the pozzolana are available, for example, as finely ground perlite with a particle size of less than 45 pm.
  • Fly ash for the purposes of this invention are z. B: Dust-like particles rich in silicic acid or lime, which are separated in electrostatic precipitators used to clean exhaust gases from coal-fired power plants.
  • High-silica fly ash consists mainly of spherical, glassy particles with pozzolanic properties and usually comes from hard coal-fired power plants.
  • Lime-rich fly ash is fine-grained dust with hydraulic and/or pozzolanic properties. They come mainly from lignite-fired plants. Fly ash can also be ground finer to increase reactivity.
  • Rice husk fly ash can also be used as fly ash.
  • Rice husk fly ash is obtained by separating the rice husk surrounding the grain, also called the husk, from the paddy rice in a rice mill. These shells are burned for energy.
  • the ash thus obtainable is rice hull fly ash and contains a high proportion of amorphous silicon dioxide.
  • blast furnace slag When iron ore is smelted in the blast furnace, blast furnace slag is produced. Granulation, ie rapid cooling of the up to 1,500 °C hot, liquid slag with water, produces blast furnace slag, a predominantly glassy, latently hydraulic material. When finely ground, granulated granulated granulated blast furnace slag develops hydraulic properties when stimulated accordingly (e.g. by the calcium hydroxide from the cement clinker).
  • Silica gel, silicate dust or microsilica are used as particulate solids or suspensions in water.
  • these consist of very fine, spherical particles with a high content (over 85% by weight) of amorphous silicon dioxide.
  • Silicate dust occurs as filter dust in the production of silicon or silicon alloys.
  • the starting material for this is quartz, which is melted together with coal in an electric furnace at temperatures from 2500 °C.
  • pozzolans are siliceous or siliceous and alumina-containing substances from natural sources. They are of volcanic origin (e.g. trass, lava) or are extracted from clay, slate or sedimentary rock (phonolite). Pozzolans do not have their own hardening capacity. They only react to form strength-forming and water-insoluble compounds when, after being mixed with water, they come into contact with calcium hydroxide (e.g. from Portland cement clinker). Pozzolan is used as natural pozzolan or as natural tempered (thermally treated) pozzolan (e.g. phonolite) for cement production.
  • Burnt slate especially burnt oil shale, is produced from natural slate deposits in a special furnace at temperatures of around 800 °C. Finely ground, burnt slate has pronounced hydraulic properties as well as pozzolanic properties.
  • Calcium oxide (CaO) and magnesium oxide (MgO) within the meaning of this invention are finely ground substances which are subject to different firing temperatures and grinding fineness during production.
  • Soft firing middle firing (also called caustic) and hard firing.
  • the firing temperature gives different reactivities which have implications for use in accordance with this invention.
  • the course of the reaction in soft firing after contact with water is, for example, fast and violent, while it is slower in medium firing.
  • the use of caustic fired products in lightweight concrete causes an expansion already in the setting phase but also in the hardened state and thus counteracts the formation of cracks and reduces the shrinkage behavior. Hard-fired materials do not achieve these properties. Therefore, only caustic calcium oxide (CaO) and caustic magnesium oxide (MgO) are used as binder additives according to this invention.
  • Finely ground perlite with a particle size of less than 45 ⁇ m is suitable as a pozzolanic additive in exchange for cement, particularly if the water/cement ratio (W/C value) is less than 0.40, preferably less than 0.35. It has been found that up to 35% by weight of cement can be replaced without loss of strength compared to mixtures containing 100% by weight of cement.
  • the exchange also has a positive effect with regard to the dry bulk density and the shrinkage behavior, both of which are reduced.
  • Graphene can also be added to the binder composition. Even when adding small amounts of 75 to 650 g/m 3 per m 3 of lightweight concrete mixture, the addition of Grahen causes a significant increase in strength, accelerated hardening and greatly reduced water absorption. Graphenes are two-dimensional, but can also be added in a preferred form with several layers, eg up to 5 or up to 10 layers.
  • Binder compositions with different chemical and physical properties can be produced. According to DIN EN 197-1, five main types of cement are distinguished:
  • Composite cements CEM V where 2. to 5. represent binder compositions because these also contain granulated blast furnace slag or other binder additives. All types of cement listed according to DIN EN 197-1 contain between 20 and 100% by weight of cement clinker.
  • binder compositions in the production of concrete in which the energy-intensive Portland cement clinker content is as low as possible.
  • the lowest Portland cement clinker content is in CEM III, which is also subdivided into CEM III A (35 to 65% by weight of ground granulated blastfurnace slag), CEM III B (66 to 80% by weight of ground blastfurnace slag) and CEM III C (81 to 85% by weight of ground blastfurnace slag).
  • a disadvantage in the production of concrete with CEM III cements is the significantly slower strength development in comparison to CEM I and CEM II, which causes significantly longer stripping times in the production of precast concrete parts.
  • the method according to the invention surprisingly achieves early strengths which are not inferior to the early strengths of CEM I or CEM II cements.
  • cements or binder compositions with a blast furnace slag content of more than 35% by weight, in particular more than 65% by weight, in particular CEM III A and CEM III B cements.
  • cements or binder compositions e.g. cements of the CEM series, with e.g. up to 70% by weight fly ash and/or up to 10% by weight microsilica can also be used.
  • cements or binder compositions are mixed with, inter alia, rice hull fly ash, e.g., up to 70% by weight.
  • Finely ground pozzolan can be added up to 35% by weight.
  • Lightweight aggregates can be used in particular alone or in a mixture. According to the invention, lightweight aggregates with low bulk densities of 40 to 1000 kg/m 3 , preferably 50 to 500 kg/m 3 or 60 to 300 kg/m 3 , can be used, the bulk density being determined according to DIN EN 1097-3. If the term “lightweight aggregates” (in the plural) is used below, it can be an essentially chemically uniform aggregate or several different lightweight aggregates. The term “lightweight surcharge” thus also includes the term “lightweight surcharge”.
  • a low grain strength means that it is less than 1 N/mm 2 .
  • a medium grain strength means that this is 1 to 5 N/mm 2 . High grain strengths are those above 5 N/mm 2 .
  • Lightweight aggregates with a low grain strength of less than 1.0 N/mm 2 can also be used according to the method according to the invention. The grain strength is determined according to DIN EN 13055 (Appendix C).
  • Suitable lightweight aggregates are (including an example explanation):
  • Pumice is a porous glassy volcanic rock. Pumice was formed by gas-rich volcanic eruptions that foamed the magma that was thrown out. Such lightweight aggregates have, for example, medium to high grain strengths and bulk densities of between 400-700 kg/m 3 .
  • Expanded clay is a lightweight aggregate manufactured industrially from expandable clay. Expanded clay is characterized, for example, by its round grain shape. Expanded clay can be obtained, for example, by drying clay, grinding it and causing it to expand at approx. 1200°C and firing it into small balls. Depending on how it is produced, expanded clay has low to high grain strengths and bulk densities of between 220 and 600 kg/m 3 .
  • Expanded slate is a lightweight mineral aggregate produced from the natural raw material slate using a thermal process. It is characterized by a compact, platy to angular grain shape and is available with a closed or open-pored surface, depending on whether or not it is crushed after firing. Expanded slate has medium to high grain strengths and bulk densities between 300 and 800 kg/m 3 .
  • Foam Lava Foam lava is a tough, volcanic rock that is fractured and shipped according to desired fractions. Foam lava has a high grain strength and bulk densities between 800 and over 1000 kg/m 3 .
  • Sintered hard coal fly ash Sintered hard coal fly ash is the result of the combustion of powdered hard coal in modern power plants. Pelleting and subsequent sintering of the balls produces a lightweight aggregate with a round grain shape and closed surface. Sintered hard coal fly ash has medium to high grain strength and bulk densities between 400 and 800 kg/m 3 .
  • Bottom ash is produced when hard coal is burned in the dry-fired boilers of power plants. Bottom ash is a water-cooled sintered product of the non-combustible mineral components of hard coal. Boiler sand has an average grain strength and bulk densities between 400 and 800 kg/m 3 .
  • Expanded glass is a purely mineral, fibre-free lightweight aggregate made from recycled glass. The waste glass is ground into glass powder and expanded at approx. 900 °C. It is generally characterized by a round grain shape and a closed surface. Expanded glass has low to medium grain strength and bulk densities between 200 and 400 kg/m 3 .
  • Expanded mica belongs to the clay minerals, it is created by the thermal processing of mica slate, a mineral created by weathering. Expanded mica can be obtained, for example, by expanding vermiculite and has low grain strength and bulk densities of between 60 and 200 kg/m 3 .
  • Expanded perlite is made from raw perlite that has been expanded in the heat. For example, raw perlite grains with a diameter of 0.2 mm to 1.2 mm can be suddenly heated to 800 to 1000° C. in a vertical furnace. The rock melts and at the same time the water it contains evaporates. The viscous melt is inflated by the steam pressure to 10 to 20 times the original volume and is carried upwards very quickly by the large air current from the hot reaction zone. As a result of the rapid cooling that takes place in this way, the expanded melt solidifies into grains with a grain size of, for example, 0 to 5 mm. Expanded perlite has low grain strength and bulk densities of 50 to 300 kg/m 3 , in particular 60 to 250 kg/m 3 .
  • the perlite Before the expansion process, the perlite can be treated with silicate, borate and/or phosphate glass to obtain the expanded perlite, preferably in an amount of 2 to 3% by weight based on the unexpanded perlite, and in particular with the addition of a nitrogen source, in particular a nitride .
  • Lightweight materials can also be used which are obtainable from a mixture of waste glass or silicon dioxide and raw perlite in a thermal expansion process and have bulk densities between 80 and 300 kg/m 3 , in particular 80 and 250 kg/m 3 (waste glass or silicon dioxide/ raw perlite mixture).
  • suitable lightweight aggregates are obtainable from vegetable substances such as, for example, wood wool shavings, expanded corn (popcorn), foamed wood fibers and plant husks, in particular rice husks. These have low bulk densities below 500 kg/m 3 .
  • Rice hull ash can also be used as a lightweight aggregate without further processing.
  • lightweight aggregates with bulk densities below 250 kg/m 3 particularly those made from expanded perlite and expanded mica, have not been used in lightweight concrete to date.
  • the main reason for this is that these lightweight aggregates are at least partially destroyed during the mixing process due to the associated reduced grain strength and have a very high level of absorption.
  • Particularly preferred lightweight aggregates are expanded perlite, expanded slate, expanded clay, expanded glass, rice hull ash and mixtures thereof, in particular with bulk densities of 40 to 1000 kg/m 3 , preferably between 50 to 500 kg/m 3 and in particular 60 to 300 kg/m 3 .
  • Concrete admixtures in the context of this invention are additives that are added to the lightweight concrete mixture in small amounts and are preferably added during production of the suspension mixture in order to improve the chemical or physical properties of the lightweight concrete mixture or those of the lightweight concrete.
  • Concrete admixtures are, for example, concrete plasticizers, plasticizers, air-entraining agents, sealants, retarders, accelerators, press-in aids, hydrophobing agents, stabilizers, fibers or shrinkage reducers.
  • polycarboxylates in particular polycarboxylate ethers, lignin sulfonates (also lignosulfonic acid), melamine formaldehyde sulfonates, naphthalene formaldehyde sulfonates, hydroxycarboxylic acids and their salts,
  • - Surfactants as air-entraining agents such as surface-active substances based on modified natural products such as root resin soaps,
  • Hydrophobing agents such as siloxanes/alkylalkoxysilanes, fatty acids, fatty acid salts, polymers (synthetic resin dispersions),
  • the fibers can be made from organic polymers (such as polyamides such as aramid or polyolefins such as polypropylene), glass, carbon, steel or basalt. Mixtures of different fibers can also be used, with the fibers being used together with the lightweight aggregates,
  • - Fillers in the form of aggregate 0 to 2 mm (grain size) with bulk densities from 2000 kg/m 3 (according to DIN EN 12620 and DIN 1405-2). They can consist of quartz rock, greywacke, basalt, dolomite, volcanic rock, slate (clay slate) and other, also recycled (according to DIN EN 12620:2008-07) aggregates.
  • the lightweight concrete can be tailored with regard to the compressive strength by the ratio of lightweight aggregate to aggregate in a dry bulk density range of 200 kg/m 3 to 1999 kg/m 3 and by the type and amount of binder composition added and the amount of water.
  • the lightweight concrete can, for example, be made pumpable and sprayable.
  • the manufacturing process comprises a two-stage mixing: a first mixing to produce a binder suspension and a second mixing comprises mixing the binder suspension produced in this way with at least the lightweight aggregates.
  • the binder suspension comprises at least the binder mixture and water. (First) mixing with a high-speed mixer differs from (second) mixing with a slow-speed mixer in that the peripheral speed when mixing with the high-speed mixer is at least 3 times higher.
  • the first step of mixing takes place with a high-speed stirring tool and has, for example, a speed of more than 100 rpm, in particular 150 rpm.
  • a peripheral speed of the stirring tool between 3 and 20 m/s, preferably between 8 and 17 m/s.
  • the second mixing step is carried out with a slow-running stirring tool and has, for example, speeds below 60 rpm, in particular below 45 rpm, for example 15 to 25 rpm.
  • the peripheral speed of the stirring tool is suitably between 0.9 and 1.25 m/s, preferably between 0.3 and 0.8 m/s.
  • the circumferential speed of the stirring tool always refers to the longest possible circumference if, for example, paddles of different lengths are used as stirring tools. If there are several mixing tools or mixing zones in a mixer, the mixing tool with the higher peripheral speed or Froude number is decisive.
  • the speed of the stirring tool is a less suitable measure because the mixing effect also depends heavily on the geometry of the stirring tool.
  • the dimensionless index according to William Froude which gives a measure of the relationship between inertia and gravity, is suitable for describing mixing and is generally divided into supercritical (mixture acceleration > gravitational acceleration; Froude number above 1.0) and subcritical (mixture acceleration ⁇ gravitational acceleration; Froude number). below 1.0).
  • the first mixing takes place in particular in such a way that the Froude number for preparing the suspension mixture is greater than 10, preferably greater than 25, and particularly preferably greater than 40.
  • the second mixing takes place in particular in such a way that the Froude number for producing the lightweight concrete mixture is less than 2, in particular less than 1.5.
  • the suspension mixture preferably has a fluidity of at least F6.
  • the lightweight concrete mixture preferably has a flowability of at least F2, preferably at least F4.
  • a suspension mixer is suitable for preparing the suspension mixture, ie the first mixing.
  • the suspension mixer includes a high-speed stirring tool.
  • the high-speed stirring tool preferably has speeds of more than 300 rpm, in particular 800 to 2000 rpm.
  • there is a peripheral speed of the stirring tool between 3 and 20 m/s, preferably between 8 and 17 m/s.
  • a particularly suitable suspension mixer referred to there as a colloidal mixer, is known from DE 10354888 B4.
  • the suspension mixer has an upper, larger-volume premixing zone and a lower, smaller-volume dispersing zone and a two-part separating element, comprising a line and a baffle plate, which spatially separates the different zones from one another.
  • the premixing and dispersing zones are each equipped with separate agitators.
  • the stirring paddles of the dispersing zone press the material to be mixed against the baffle plate, which is arranged above the stirring paddle zone of the dispersing zone and has a circular recess in the middle.
  • the mixed material then hits the line, which is arranged above the baffle plate and has a smaller diameter than the baffle plate with regard to its outside and inside diameter.
  • the material to be mixed is pushed outwards and upwards along the line and is pressed into the premixing zone through a circumferential outer ring slot between the line and the inner wall of the mixer.
  • the mixed material then collapses in the middle of the premixing zone and thus returns to the dispersing zone through the first separating element, the line, seen from above.
  • Another suitable suspension mixer is known from DE 102011102988 A1, having an upper circulation zone/premixing zone and a lower dispersing zone, with at least one mixing tool having a mixing axis and mixing paddles being provided in the dispersing zone and at least one separating element spatially delimiting the circulation zone and dispersing zone from one another and the separating element releases at least one outer passage remote from the stirring axis and one inner passage near the stirring axis, the inner passage brings about the flow of material from the circulating zone in the dispersing zone and the outer passage brings about the flow of material from the dispersing zone into the circulating zone and the outer passage is arranged above the level of the mixing paddles, with at least the outer passage can be changed in its (total) passage area from the outside during the mixing process.
  • the suspension mixer according to DE 102011102988 A1 preferably has two chambers (premixing zone and dispersing zone).
  • the material to be mixed is moved passively in the premixing zone by the outlet of the liquid material to be mixed via a separating element, with the material to be mixed being initially sucked into the dispersing zone via a larger inlet in the separating element, preferably arranged above the axis of rotation.
  • the mixture is caught by a high-speed agitator and pressed radially outwards, preferably also upwards, with the mixture passing in the flow direction through smaller openings in the cutting disc or through smaller openings between the outer edge of the cutting disc and the container wall.
  • the smaller openings are preferably located on the outer periphery of the cut-off wheel. In this case, smaller and larger designate the relative area ratio of the smaller outlet openings to the larger inlet opening(s) in the dispersing zone.
  • the second mixing comprises mixing the suspension mixture so produced with at least the lightweight aggregates.
  • Free-fall mixers or cone mixers are suitable for this if they are operated at a low speed or low peripheral speed.
  • the free-fall mixer is available in very different sizes. As a small device with a volume of a few liters, they are widespread in the do-it-yourself and sometimes also in the craft sector for use on construction sites. In industrial sizes with a capacity of 0.5 and more cubic meters, they are used stationary in ready-mixed concrete and precast plants.
  • the basic principle is the same. The mixing process takes place in a rotating drum. The drum is also fed through the drum opening. Inside the drum is a spiral or paddles fixed to the drum wall, which picks up and lifts part of the mix with each rotation.
  • Cone mixers have lateral scrapers on the lower cone wall and a central shaft with an Archimedean screw and/or inclined paddles attached to the central shaft and/or a combination thereof.
  • This type of mixer with a mixing chamber that narrows conically towards the bottom is characterized by the fact that the material to be mixed is transported from the bottom upwards during mixing due to the design and, due to the design, detaches laterally from the auger/paddles and then falls again in free fall via gravity moved below.
  • Both the centrically arranged shaft/axis and the scraper can be operated at different speeds. Depending on the speed set, the cone mixer is therefore able to work with a Froude number greater than 10 or greater than 25, as well as less than 2.5 or less than 1.5.
  • the lightweight concrete if it is produced as a structural element, has cover layers on at least one, preferably on both main surfaces (ie the two large areas of the structural element).
  • a first layer which is thinner than the lightweight concrete mixture according to the invention, can be introduced from another, hydraulically hardening material with a predetermined application thickness, to which the lightweight concrete according to the invention is applied. connects and hardens.
  • a second layer of the same or another hydraulically hardening material which also combines with the lightweight concrete according to the invention, can be applied. Elements coated on one and/or both sides with a cover layer can thus be produced simply, quickly and inexpensively.
  • the hydraulically setting material can be a so-called plaster system comprising a plaster mortar.
  • Such a cover layer can, for example, also consist of a set inorganic plaster binder, also a plaster binder slurry.
  • a reinforcement, in particular in the form of a fiber mat can preferably be embedded in the cover layer.
  • the fiber mat can consist of glass fibers, carbon fibers and/or basalt fibers.
  • the fiber mat can also be provided solely in the edge or edge regions of the component in order to strengthen the edges. It is also possible during the production process, before filling the formwork with the lightweight concrete mixture according to the invention, to insert fiber mats to protect against shrinkage cracks and as a primer for subsequent coatings, or to apply them after at least partial curing. This means that preparations can be made on both sides for the subsequent surface treatment.
  • a lightweight concrete mixture according to this invention into the shell mold, which can assume static functions as a lightweight concrete layer with appropriate density and compressive strength on the building, and to apply a highly insulating lightweight concrete of lower density to this pressure-resistant lightweight concrete, produced according to this invention.
  • a commercially available adhesion promoter can be applied for better adhesion between the different lightweight concretes, but it is also possible to work “wet on wet” and thus dispense with an adhesion promoter.
  • pressure-resistant lightweight concrete to the highly insulating lightweight concrete. This creates a sandwich in which the pressure-resistant lightweight concrete takes on the static and protective function and the highly insulating lightweight concrete with low density provides insulation and additional soundproofing.
  • a so-called gradient concrete can be produced, whereby concrete, where this is statically required, with higher density and compressive strength and at the points where, for example, thermal insulation and/or weight saving play a role, lightweight concrete according to this Invention is used, in principle, the transition of different types of concrete can also be done continuously or wet in wet.
  • the lightweight concrete according to the invention fulfills the function of thermal insulation and/or additional sound insulation, while normal concrete fulfills static and functional properties.
  • a light-weight concrete with a lower density than normal concrete into the pouring form, then to lay a commercially available insulation on or to insert such as, for example, low-density mineral foam ( ⁇ 100 kg/m 3 ), mineral fiber insulation boards, polyurethane insulation boards, rigid foam boards, polystyrene rigid foam boards, Cork boards, wood fiber boards, cellulose fiber boards, sheep's wool, wood shavings, etc., and then again a lightweight concrete according to this invention and permanently connect the two lightweight concretes by means of concreted-in connecting means, whereby the densities and compressive strengths of the lightweight concretes can differ.
  • the more pressure-resistant lightweight concrete can, for example, assume static functions as the inner shell of a sandwich façade.
  • load-bearing and static reinforcements can be placed in the mold. Also so-called supporting structures, as described in EP 0808959 B1.
  • the aforementioned types of reinforcement are inserted into the mold before the lightweight concrete according to the invention is poured, surrounded by the latter and, after the lightweight concrete has hardened, assume the desired functions as a transport aid, static functions and connections and joining aids on the building.
  • all common carrying aids and fasteners can be set in concrete by placing them in the mold before pouring the lightweight concrete and encasing them after pouring.
  • all types of hollow bodies can also be introduced in order to achieve a further reduction in the weight of the building product made from the lightweight concrete according to the invention.
  • the lightweight concrete can be placed in a climatic chamber after it has been poured into a mold, in particular a formwork mold.
  • a curing climate can be set in this climatic chamber by means of warm air and/or superheated steam, which can be set to 30 to 85° C., in particular 35 to 60° C., depending on the binders used, with regard to the chamber temperature.
  • the residual moisture content of the lightweight concrete at dry bulk densities from 1200 kg/m 3 is preferably below 16% by weight, particularly preferably below 14% by weight or even below 13% by weight.
  • Microsilica Silicon P, Sika
  • Hydrophobing agent Protec HWA(ST) HA-BE, Ha-Be Betonchemie GmbH, Hameln, Germany (stearate)
  • Foaming agent SB 2, Mapei
  • Lightweight aggregate 1 expanded perlite with a grain size of 0-5 mm
  • Perliopol Lightweight aggregate 2 Fibo ExClay with a grain size of 2-5 mm (expanded clay)
  • the suspension mixture, lightweight aggregate 1 and fibers were homogeneously mixed in a free-fall mixer with a Froude number of 0.3 (drum revolution 0.5 revolutions per second). It was 30 I lightweight concrete mix after 180 see. (From the addition of the suspension mixture) obtained.
  • the flowability was defined using the slump classes F1 to F6 according to DIN EN 12350-5.
  • the dry raw density has been measured according to DIN EN 12390-7 in a heating cabinet at 105 °C.
  • the average water/B (W/B) value is the ratio between the mass of water and the mass of the binder with the limestone powder (if used), microsilica and CaO as the fly ash added to the binder.
  • Composition 1 according to the above test procedure: The lightweight concrete mix had a flowability of F6 and a water-to-binder ratio of 0.32.
  • the lightweight concrete produced in this way had a raw dry density of 351 kg/m 3 and an average compressive strength of 2.5 N/mm 2 and a thermal conductivity (lambda value X) of 0.095 (W/m 2 K).
  • Composition 2 produced according to the above test procedure, except that the lightweight aggregates were placed in the free-fall mixer together with the fibers and the aggregate.
  • the lightweight concrete mixture had a flowability greater than F6 and a water to binder ratio of 0.36.
  • the lightweight concrete produced in this way had a raw dry density of 581 kg/m 3 and an average compressive strength of 7.8 N/mm 2 after 28 days.
  • compositions 3 and 4 were prepared by first placing water in a suspension mixer according to DE 102011102988 A1 (20 l), switching on the agitator and adding in succession: a) for composition 3: cement, fly ash, aggregate 0-2 mm and the concrete additives and b) for composition 4: cement, limestone powder, microsilica and aggregate 0-2 mm and the concrete additives.
  • the mixing took place in the suspension mixer with a Froude number of 91.4 (mixing paddle speed, peripheral speed 13 m per second) to form a suspension mixture within 240 seconds. (from cement addition).
  • the suspension mixture had a flowability greater than F6.
  • the suspension mixture was then immediately poured into a gravity mixer (Atika, 50I), in which the 2-8 mm aggregate together with the fibers had already been placed and premixed. Then, while the tumbler continued to mix, 50% of the suspension mixture was added, followed by 50% of Lightweight Aggregate 1, then the remaining 50% of the suspension mixture, and then the remaining Lightweight Aggregate 1. Mixing in the tumbler was done with a Froude number of 0 .3 (0.5 revolutions per second). It was 30 I lightweight concrete mix after 240 see. (From the addition of the suspension mixture) obtained.
  • Composition 3 Composition 3:
  • the lightweight concrete mixture had a flowability greater than F6 and an average water-to-binder value of 0.40.
  • the lightweight concrete produced in this way had a dry bulk density of 1,214 kg/m 3 and an average compressive strength of 28 N/mm 2 after 28 days.
  • Composition 4 The lightweight concrete mixture had a flowability greater than F6 and an average water-to-binder value of 0.41.
  • the lightweight concrete produced in this way had a dry bulk density of 1,649 kg/m 3 and an average compressive strength of 48 N/mm 2 after 28 days.
  • compositions 5 and 6 were prepared by first placing water in a suspension mixer according to DE 102011 102988 A1 (20 l), switching on the agitator and adding in succession: a) for composition 5: cement, aggregate 0-2 mm and the concrete additives and b) for composition 6: cement, fly ash, and the concrete additives
  • Composition 5 is a composition of Composition 5:
  • the lightweight concrete mix had a flowability of F6 and a water-to-binder ratio of 0.44.
  • the lightweight concrete produced in this way had a dry bulk density of 1,275 kg/m 3 and an average compressive strength of 34 N/mm 2 after 28 days.
  • the lightweight concrete mixture had a flowability greater than F6 and an average water-to-binder value of 0.42.
  • the lightweight concrete produced in this way had a dry bulk density of 1,551 kg/m 3 and an average compressive strength of 42 N/mm 2 after 28 days.
  • compositions 7 For the compositions 7, the production took place in such a way that water was first introduced into the suspension mixer according to DE102011102988 A1 (20 l) and ground blast furnace slag and activator were added. Both were premixed and then the fly ash and the concrete additives were added. The mixing took place in the suspension mixer with a Froude number of 91.4 (mixing paddle speed, peripheral speed 13 m per second) to obtain the suspension mixture within 240 seconds. (from the addition of blast furnace slag). The suspension mixture had a flowability greater than F6.
  • Composition 7 is a composition of Composition 7:
  • the lightweight concrete mixture had a flowability greater than F6 and an average water-to-binder value of 0.46.
  • the lightweight concrete produced in this way had a dry bulk density of 1,540 kg/m 3 and an average compressive strength of 38 N/mm 2 after 28 days.
  • the lightweight aggregate 2 was then poured in at the same mixing speed and mixed for a total of a further 180 seconds. Subsequently, with a Froude number of 0.9 (1.2 screw revolutions per second), the lightweight aggregate 1 with the ingredients of the lightweight concrete mixture was added within 240 seconds. (from the addition of lightweight aggregate 1) mixed homogeneously to form a lightweight concrete mixture.
  • the lightweight concrete was filled into molds and placed in a curing chamber, which was heated to around 40 °C, for 20 hours and then the formwork was removed.
  • Composition 8 is a composition of Composition 8:
  • the lightweight concrete mix had a flowability of F4 and a water-to-binder ratio of 0.42.
  • the lightweight concrete produced in this way had a dry bulk density of 1,489 kg/m 3 and an average compressive strength of 31 N/mm 2 after 28 days.
  • the increase in strength compared to mixing without aggregate was 51% after 20 hours and 27% after 28 days.

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  • Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)

Abstract

L'invention concerne un procédé de production de mélanges de béton légers à l'aide d'agrégats légers, comprenant un procédé de mélange en au moins deux étapes, selon lequel un mélange en suspension comprenant la composition de liant est préparé par agitation à grande vitesse avec un ciment ou un géopolymère et de l'eau, puis le mélange en suspension est mélangé par agitation à faible vitesse avec des constituants comprenant les agrégats légers. L'invention concerne également les bétons légers et les mélanges de béton légers ainsi produits. Les compositions de liant candidates comprennent, par exemple : - 60 à 80 % en poids de laitier sable ciment finement broyé, 10 à 60 % en poids de cendres volantes - 2 à 25 % en poids d'hydroxydes de métal alcalin/silicates de métal alcalin, 75 à 98 % en poids de laitier sable finement broyé - 2 à 20 % en poids d'hydroxydes de métal alcalin/silicates de métal alcalin, 60 à 78 % en poids de laitier sable finement broyé - 20 à 38 % en poids de cendres volantes ciment, 30 à 50 kg/m3 (dans le mélange de béton léger) de microsilice ciment, 10 à 60 % en poids de balle de riz cendres volantes ciment, 1 à 5 % en poids de CaO/MgO caustique calciné.
EP21847981.4A 2021-12-31 2021-12-31 Procédé de production de mélanges de béton légers à l'aide d'agrégats légers Pending EP4304823A1 (fr)

Applications Claiming Priority (1)

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PCT/EP2021/087908 WO2023126069A1 (fr) 2021-12-31 2021-12-31 Procédé de production de mélanges de béton légers à l'aide d'agrégats légers

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EP4304823A1 true EP4304823A1 (fr) 2024-01-17

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EP21847981.4A Pending EP4304823A1 (fr) 2021-12-31 2021-12-31 Procédé de production de mélanges de béton légers à l'aide d'agrégats légers

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US (1) US20250187979A1 (fr)
EP (1) EP4304823A1 (fr)
JP (1) JP2025501326A (fr)
CN (1) CN118660794A (fr)
AU (1) AU2021481041A1 (fr)
MX (1) MX2024008267A (fr)
WO (1) WO2023126069A1 (fr)

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DE102023208724A1 (de) 2023-09-08 2025-03-13 Xella Technologie- Und Forschungsgesellschaft Mbh Verfahren zur Herstellung von hydrothermal gehärteten Poren- oder Schaumbetonformkörpern und mittels des Verfahrens hergestellter Poren- oder Schaumbetonformkörper
DE102024121786A1 (de) 2024-07-31 2026-02-05 Gp-Cem Ltd Zementfreies säurebeständiges alkalisches Bindemittel
WO2026068190A1 (fr) * 2024-09-30 2026-04-02 Sonocrete GmbH Suspension composite pour la production de béton, utilisation de la suspension composite, procédé de production d'une suspension composite stabilisée et procédé de production de béton
EP4717687A1 (fr) * 2024-09-30 2026-04-01 Sonocrete GmbH Suspension de liant pour la préparation de béton et procédé de préparation d'une suspension de liant
CN120965200B (zh) * 2025-09-04 2026-05-12 南通盛和益新材料科技有限公司 基于碳基磁性材料的轻质混凝土吸波材料及其制备方法

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JP2025501326A (ja) 2025-01-17
CN118660794A (zh) 2024-09-17
AU2021481041A1 (en) 2024-07-25
WO2023126069A1 (fr) 2023-07-06
US20250187979A1 (en) 2025-06-12
MX2024008267A (es) 2024-07-19

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