WO2002006182A1 - Composition de mortier et procede de production correspondant - Google Patents

Composition de mortier et procede de production correspondant Download PDF

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Publication number
WO2002006182A1
WO2002006182A1 PCT/AU2001/000852 AU0100852W WO0206182A1 WO 2002006182 A1 WO2002006182 A1 WO 2002006182A1 AU 0100852 W AU0100852 W AU 0100852W WO 0206182 A1 WO0206182 A1 WO 0206182A1
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WIPO (PCT)
Prior art keywords
weight
parts
mortar composition
cement
mortar
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Ceased
Application number
PCT/AU2001/000852
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English (en)
Inventor
Liam P. Devlin
Edita Grujic
Samuel Moses
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DAVCO CONSTRUCTION MATERIALS Pty Ltd
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DAVCO CONSTRUCTION MATERIALS Pty Ltd
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Priority to AU2001272205A priority Critical patent/AU2001272205B2/en
Priority to AU7220501A priority patent/AU7220501A/xx
Publication of WO2002006182A1 publication Critical patent/WO2002006182A1/fr
Anticipated expiration legal-status Critical
Ceased 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
    • C04B28/02—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
    • 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
    • C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • C04B18/248—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork from specific plants, e.g. hemp fibres
    • 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
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00672—Pointing or jointing 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 an improved mortar composition.
  • the invention relates to a mortar composition containing untreated rice husks and which composition can exhibit higher mileage and lower density than standard mortar compositions.
  • the present invention also relates to a method for the preparation of said mortar composition.
  • Hydraulic cements have been used for thousand of years as the agents in adhesives, cement pastes, mortars, grouts, cement panels and bricks, and concrete.
  • the hydraulic cement- based materials are formed by mixing hydraulic cement with water and one or more fillers, which are either simultaneously or subsequently blended into the mixture.
  • the existing minerals in the cement either decompose or combine with water, and a new phase (such as a calcium-silicate-hydrate structure) forms throughout the material.
  • the water-cement mixture containing the fillers sets and then cures.
  • Wetted hydraulic cements are typically used as an adhesive between two substrates such as a concrete floor or wall and a ceramic tile, between bricks or cinder blocks, as a filler, sealant or stucco, as individual bricks or cement panels, or with the addition of aggregates as concrete blocks, footpaths, roads, columns, walls, floors, supports or other such structures.
  • cellulosic material as a filler or extender for hydraulic cement compositions has been previously described.
  • the use of fillers or extenders gives rise to new cement compositions having unique and advantageous qualities, in addition to extending the coverage of the cement composition, and, where the filler has a low density, in making light-weight cement based compositions and products.
  • the use of such cellulosic material often retards cementitious compositions resulting in products having lower strength, poorer keeping qualities by being susceptible to rotting and degradation, and lower impact resistance.
  • Portland cement bonded lignocellulosic materials are known to have a detrimental effect on the strength and quality of cement compositions.
  • Typical lignocellulosic materials which cause retardation include various wood particles such as rice husks, jute sticks, coir, sawdust, coconut pith, banana stem fibre and wheat straw. It is thought that in the setting of cement-wood particle compositions that a weak boundary layer is formed between the calcium silicate hydrate and the wood particles as a result of the dissolution of polysaccharide and lignin released during the setting of the cement by calcium hydroxide. The addition of wood particles to cement compositions gives rise to weak and inferior products as a result of the poor adhesive forces operating between wood particles and the hydrated products of cement [see Singh, S.M., J Indian Acad. Wood Sci., 10(l) pl5-19 (1979)].
  • Japanese patent application No. 55-144072 describes heat-treated vegetable fibrous material used as a filler for adhesives.
  • the vegetable fibrous material such as wood powders, leaves, barks, spike axes of maize or rice hulls, is optionally ground, then heat- treated by contacting it with saturated steam or superheated steam at preferably an elevated pressure.
  • the heat-treated material is dried to a moisture content of 3-15%, and is then blended with a filler with an adhesive based on a resin such as a urea resin, a melamine resin or a phenol resin.
  • Chinese patent application No. 1060428 describes the preparation of thermal-insulating board with treated rice husks.
  • the rice husks are antiseptically treated by immersion and boiling, followed by binding together with an adhesive and pressing to form a husk board, and finishing with a water-proof cement sealing coat to obtain thermal-insulating board.
  • Further advantageous outcomes achievable by embodiments of the present invention include the provision, of mortar compositions at a reduced cost and which are lighter but as strong and durable as known mortar compositions commonly used in the building industry.
  • the present inventors have surprisingly found that particulate cellulosic material such as untreated rice husks can be used to extend hydraulic cement compositions, whilst the compositions still exhibit acceptable tensile and shear strengths.
  • the hydraulic cement compositions of the present invention comprise cement, rice husks, at least one or more fillers and additives and an accelerator.
  • a mortar composition which comprises: a) 100 parts by weight of cement; b) 1-80 parts by weight of untreated rice husks; c) 30-200 parts by weight of at least one or more fillers and additives; and d) 0.2-10 parts by weight of an accelerator.
  • a method of making a mortar composition comprising the step of mixing together in any order: a) 100 parts by weight of cement; b) 1-80 parts by weight of untreated rice husks; c) 30-200 parts by weight of at least one or more fillers and additives; and d) 0.2-10 parts by weight of an accelerator.
  • the present invention also provides mortar compositions prepared by the above method.
  • a settable mortar composition which comprises: a) 100 parts by weight of cement; b) 1 -80 parts by weight of untreated rice husks; c) 30-200 parts by weight of at least one or more fillers and additives; d) 0.2-10 parts by weight of an accelerator; and e) 30-150 parts by weight of water.
  • a method of making a settable mortar composition comprising the step of mixing together in any order: a) 100 parts by weight of cement; b) 1-80 parts by weight of untreated rice husks; c) 30-200 parts by weight of at least one or more fillers and additives; d) 0.2-10 parts by weight of an accelerator; and e) 30-150 parts by weight of water.
  • a method for setting a tile on a supporting surface comprises trowelling onto the supporting surface a settable mortar composition of the present invention and setting the tile into the mortar composition to adhere the tile to the supporting surface.
  • cement refers to binder materials that harden to form a connecting material between solids and typically include any mixture of finely-ground lime, alumina, and silica that will set to a hard product and which combine with other ingredients to form a hydrate such as Portland cement, hydraulic cements, blended cement and masonry cement, mortar, grout, and may also have added fillers, aggregates and/or other additives including hydrated lime, limestone, chalk, shell, talc, slag or clay.
  • wood is taken in its broadest sense to mean a hydraulic cement composition such as a masonry cement, grout, tile adhesive, filler, screed, stucco or plaster especially suited to bind bricks, stones, tiles, blocks and the like either together or to other substrates.
  • Ordinary Portland cement is a hydraulic cement produced by pulverising Portland cement clinker and typically is classified as one of 8 Types: I; II; III; IN; V; la; Ila; and Ilia. Variations in the colour of the cement may exist such as white Portland cement or grey Portland cement, or the cement may also be pigmented or coloured if required.
  • hydraulic cement compositions can be prepared with cellulosic material such as wood-based particles which compositions maintain an acceptable level of tensile, bond and shear strength, durability, flexibility, resilience and resistance to cracking and breaking of the bond or the substrate whilst gaining substantial advantages in extending the mileage of cement compositions.
  • the coverage of cement compositions when used as mortars and tile adhesives is significantly increased by the addition of cellulosic material without significantly compromising strength, and in some cases maintaining the strength of the hardened cement.
  • the cement compositions of the present invention also have lower densities than those without the added cellulosic material.
  • the wood-based cellulosic particulate material of the present invention is untreated rice husks.
  • Rice husks are readily available as a byproduct of the rice-growing industry and have excellent utility in the cement compositions of the present invention.
  • the rice husks (or hulls) are most preferably used untreated by any chemical processing step.
  • the rice husks are obtained from the bran or outer sheath of the rice grain separated during normal milling of rice.
  • the sheer volume of rice grown and milled around the world means that thousands of tonnes of waste rice husks are produced annually, providing an inexpensive and reliable source of the cellulosic extender for use in the mortar compositions of the present invention.
  • the use of untreated rice husks in the mortar compositions addresses environmental concerns as to how to dispose of the waste rice husks.
  • the husks are used as is, untreated, without any chemical processing as typically required in prior art methods and compositions.
  • utilising the untreated husks lowers processing costs, minimises plant costs and obviates the need of disposing of chemical processing wastes from chemically treating the rice husks.
  • the rice husks may be used as is or sized according to the application in which they will be applied. For example where the mortar composition is to be used as a screed, stucco, rendering composition or the like, the husks can be used as is.
  • the size of the husks may be reduced by, for example, grinding with sand or other abrasive techniques well known in the art. Grinding the rice husks produces a range of smaller particle sizes which again may be used as is or sieved to give particular size ranges.
  • the size of the rice husk particles allows for the wetted mortar composition to flow more easily. If the rice husk particles are too large the ability for wetted compositions to be spread with a grooved trowel for example is diminished as the husks tend to clump and stick together in the grooves.
  • the rice husks obtained from the milling of rice are simply dried, and if desired can be sieved to obtain a preferred particle size distribution. Rice husks may be ground or milled and then sieved to provide a more preferred size range and better distribution of rice husks as required.
  • the untreated rice husks for use in the present invention are preferably from 1-80 parts by weight (based on 100 parts by weight of cement), more preferably 20-40 parts by weight, and most preferably 30-35 parts by weight.
  • the untreated rice husks are preferably in the size range of 100-600 microns, more preferably 150-500 microns.
  • the untreated rice husks are added to mortar compositions of the invention, either in addition to the existing components or by replacing some of the filler to keep the cement ratio constant as required.
  • the present inventors have found that the judicious choice of accelerator or setting aid can overcome the problem that particulate cellulosic material such as untreated rice husks do not bind well with wetted cement compositions and the cellulosic material retards the strength of the cement composition once set.
  • the accelerators are selected from C -4 carboxylic acid salts.
  • the carboxylic acid salt is formate, acetate, propionate, oxalate or malonate more preferably formate or acetate, most preferably formate, whilst the counter ion is preferably calcium.
  • other counter anions such as magnesium, potassium, lithium, sodium, ammonium or the like can be used where there is a high calcium cation content in the mortar compositions of the invention provided by fillers, additives or other accelerators.
  • standard and common accelerators on their own such as lithium carbonate or calcium chloride gives no significant or real advantage in compensating for the retardant properties of the untreated rice husks.
  • nitrate salts and most preferably calcium_nitrate as a suitable accelerator for the mortar compositions of the present invention.
  • the accelerator is in an amount of 0.2-10 parts by weight (based on 100 parts by weight of cement), more preferably 2-6 parts by weight, and most preferably about 4 parts by weight.
  • the accelerators of choice in the present invention work by restoring the strength lost by addition of the particulate cellulose material to the hydraulic cement compositions.
  • calcium formate and other accelerators are able to offset the retardation caused by the untreated rice husks in the mortar compositions of the invention.
  • a further advantage in using untreated rice husks is their ready availability in bulk on a multi-tonne scale.
  • the rice husks are used untreated, eliminating the need to perform any chemical pre-treatment steps.
  • the husks may be physically treated, such as for example simple washing to remove unbound polysaccharides, drying or grinding and/or sieving to preferred particle size ranges or distributions.
  • the mortar compositions of the present invention preferably contain at least one inert filler.
  • Fillers that may be used include aggregate filler, fine filler or a combination of aggregate and fine fillers.
  • the inert filler additive may be silica sand, limestone, perlite, volcanic aggregate, alumina trihydrate, ground quartz, volcanic ash, fine sand, talc, mica, clays, calcium carbonate (marble dust), other clean inert material or mixtures of the foregoing.
  • the fillers are often fine fillers, typically with particle sizes in the range of 1 microns to many millimetres in diameter and may include the following materials: silica or alumina materials such as fine or ground sand, ground silica, colloidal or precipitated silica and corundum; carbonates such as natural or surface treated magnesium or calcium carbonate, or a calcium, barium or magnesium carbonate such a dolomite; sulfates such as calcium sulfate, for example, hydrated plaster and gypsum, insulation materials such as expanded glass or clays, vermiculite, perlite and celite; expanded plastics such as polystyrene and polyurethane; crumbed rubber; metal filings; shortmilled fibres, mica and other such materials.
  • silica or alumina materials such as fine or ground sand, ground silica, colloidal or precipitated silica and corundum
  • carbonates such as natural or surface treated magnesium or calcium carbonate, or a calcium, barium or magnesium carbonate
  • Sand and other such fine aggregates used as fillers in the mortar compositions of the present invention typically have particle sizes in the range of substantially 0.1 mm to 6 mm and may include the following materials: common or silica sand, light weight aggregates such as perlite, vermiculite, fly ash, pumice, expanded clay, expanded polystyrene beads and carbon beads.
  • the mortar compositions of the present invention may be used as grout, mortar, backerboard, floor screed, stucco and as a tile adhesive in construction and building projects.
  • Mortar, adhesive, grout, backerboard, screed and stucco are all cementitious products similar in composition but designed, applied and used for different but related objectives.
  • grout is a thinner mortar used for the filling of spaces between tiles and masonry to provide a finish comparatively level with the surfaces of the tiles and masonry, for both aesthetics and ease of maintenance. When the grout solidifies it provides a monolithic structure to the multitude of tiles, bricks or other products that have been grouted.
  • Grout is a bonding agent which must bond well into the spaces in which it is applied to.
  • Mortar or adhesive is a basic combination of a fine particulate filler such as fine sand and Portland cement.
  • the adhesive is used as a bonding agent for the laying of tiles, bricks and other masonry products onto a substrate such as a wall, floor or backerboard.
  • tile adhesives are used exclusively as a bonding agent to create the adherence of two separate substrates, such as tile to concrete.
  • Backerboard is a solid sheet of cementitious material which provides a sound and stable substrate for the installation of tiles and masonry materials, such as ceramic tiles or thin brick veneer. Backerboard is used as a substrate to which other products are bonded to, such as with mortars, adhesives and mastics.
  • a proper substrate In the setting of tiles, a proper substrate must first be in place to support the tiles that are then bonded to the substrate. Concrete floors may require some degree of levelling with, for example, cement pastes and fillers onto which the tiles are then applied.
  • the mortar compositions of the invention also find utility as such cement pastes and fillers.
  • Other substrates known to those skilled in the art such as backerboard or metal lath with cement plaster applied to it may find utility as an adequate substrate.
  • the tiles With the substrate in place, the tiles are set into a wetted mortar or adhesive composition.
  • the mortar or adhesive is generally trowelled onto the surface of the substrate using a ridged trowel which provides for ridges of typically about 12 mm in height and spacing.
  • any ridges present permit the air to escape from under the tile and also provides areas into which the mortar may spread when the tile is set.
  • the hydraulic cement compositions of the invention may also be used in the production of pre-mix concrete.
  • concrete is broadly defined as a hard, strong building material made by mixing a water-hydraulic cement mixture with an aggregate such as sand, gravel, other geologic materials, metals and/or metallic alloys having a typical particle size in the range of 6 mm to 50 mm.
  • the cement acts as a "glue” to bind the aggregate particles together in the concrete.
  • the physical properties of concrete vary depending upon many variables including the cement composition, the choice of aggregates, and the processing technique. Concrete is commonly used to construct driveways, * footpaths, foundations, floors, roads, walls, supports and other such structures.
  • mortar compositions can be substantially affected by varying the amount of water added to the cement composition mixture prior to setting and hardening. Typically, reducing the amount of water tends to improve the strength of the set and hardened product. However a certain minimum amount of water is needed in order to obtain the required workability or fluidity, and so water content may be reduced if special techniques are used such as: adding plasticisers to the fresh mix; selecting a proper grading of aggregates used in the mix; selecting greater amounts of high aluminous cements in place of Portland cements; using vibration to place the mix which means less workability is needed; removing water after the fresh mix is in place; and by adding latexes.
  • the amount of water required to be mixed with the hydraulic cement compositions of the invention is preferably 30-150 parts by weight (based on 100 parts by weight of cement), more preferably 60-100 parts by weight. However, it will be understood that those skilled in the art may vary the amount of added water depending on various factors such as rate of setting required, amount of latex to be added, desired workability of the wet mixture and the like.
  • pre-moisten the surface of the substrate to limit the amount of liquid absorbed from the settable mortar composition by the substrate, particularly where porous substrates are used.
  • Such pre- moistening or cleaning can be accomplished through a variety of ways as known to those skilled in the art.
  • the mortar compositions of the present invention may also contain elastomeric or amorphous thermoplastic polymer particles as redispersable powders or dispersions.
  • the main elastomeric latexes are natural rubber, styrene butadiene, polyacrylonitrile butadiene, polychloroprene.
  • the primary thermoplastic latexes are: polyvinylacetate, polystyrene, polyvinylchloride, polyacrylates, or their copolymer. Latexes allow reduction of the amount of water used in the preparation of the settable cement compositions since the latexes have a plasticising effect on the mix.
  • Latexes also form a 3 -dimensional film throughout the mortar or concrete on drying and this provides additional beneficial effects such as higher strength, -greater wear resistance, greater durability, greater flexibility and improved resistance to chemical attacks. Latex modified mortars and concretes typically also have a much higher bonding strength with other materials compared to unmodified cement based mortars and concretes.
  • latexes are added to mortar or concrete by adding a small amount of latex to the fresh mix and reducing the amount of water to the extent that the same workability is attained.
  • the latex modified mortar or concrete can be obtained with a smaller water/cement ratio of up to about 35%.
  • the latex additives are typically anionic and nonanionic dispersions in water, usually containing approximately 50% by weight of water, and this water must be considered as part of the mixing water.
  • the mortar compositions of the present invention optionally contain further additives which assist in controlling the curing rate, strength on setting and hardening and general properties of the compositions.
  • additives may include suspension enhancing agents which decrease the settling of components thereby aiding the stabilisation of the cement composition.
  • suspension enhancing agents include cellulose ethers, animal glues, starches, polyvinyl alcohols, proteins, gums, clays and any combination of the foregoing.
  • Setting aids are optionally employed in cement compositions to help promote faster, harder curing and/or to prevent efflorescence.
  • the most common setting aids are salts that provide free calcium ions to the aqueous component and such salts typically include calcium chloride, calcium sulfate and calcium nitrate.
  • a dispersant or a surfactant may be used as dispersants.
  • the most preferred dispersants are anionic or nonionic surfactants as well known in the art. Additional dispersant aids such as sodium naphthalene formaldehyde sulfonates or sulphonated melamine formaldehydes may also be used.
  • preservatives, antifoaming agents or other miscellaneous enhancing additives such as alkylene glycols, chlorinated paraffins, and alkali metal fatty acid salts as known to those skilled in the art.
  • the fillers and additives used in the mortar compositions of the present invention are preferably one or more of calcium carbonate, hydroxy alkyl cellulose ethers, ethylene/vinyl acetate copolymers and terpolymers and the like, polyvinyl alcohol, hydrated lime, and fine sands present in a total amount of 30-200 parts by weight (based on 100 parts by weight of cement), preferably about 30-150 parts by weight and more preferably about 45- 120 parts by weight.
  • the fillers and additives based on 100 parts by weight of cement include: - calcium carbonate present in up to 25 parts by weight, more preferably about 3-16 parts by weight;
  • hydroxy alkyl cellulose ethers in the range 0.1-3 parts by weight, more preferably about 0.2-1 parts by weight and preferably consists of water soluble thickeners and colloids such as but not limited to hydroxy propyl methyl cellulose, hydroxy ethyl cellulose, ethyl hydroxyethyl cellulose, acrylamide modified polymers, starches, polysaccharides, xanthan gums, other thickeners well known in the art and mixtures thereof;
  • - ethylene/vinyl acetate copolymers in the range 0.1-10 parts by weight, more preferably about 1-3 parts by weight; - polyvinyl alcohol in the range 0-10 parts by weight, more preferably about 0.7-4 parts by weight; hydrated lime in the range 0-6 parts by weight, more preferably about 2 parts by weight; and
  • - fine sand in the range 25-150 parts by weight, more preferably about 30-110 parts by weight, and typically having a nominal particle size range of about 150-500 microns.
  • a setting aid may be present in amounts from about 0.01 to about 20 parts by weight (based on 100 parts by weight of cement) of a setting aid, an antifoaming agent, a glycol, a latex, a waterproofing agent, a preservative, antimicrobial agent, an additional setting aid or mixtures thereof.
  • the components of the mortar compositions may be added together in any preferred order and may be mixed typically by agitation, rolling or shaking. It will also be obvious that two or more components may be mixed together and at a later time further compounds added to make the mortar compositions of the invention. Any such variations in the order of mixing the compounds in the preparation of the mortar compositions are contemplated by the invention, including the pre-mixing of the untreated rice husks with the accelerator, in particular the carboxylic acid salt, with or without water or moisture, prior to the addition of the remainder of the components.
  • the hydraulic cement compositions of the invention show particular utility as mortars and tile adhesives.
  • Mortar compositions of the invention are able to achieve excellent shear and bond strengths to industry standards, such as the Australian Standard AS 2358, and exhibit desired properties; whilst at the same time being able to be formulated at similar or lower costs per square metre covered than most presently known mortar compositions.
  • the carboxylic acid salt accelerator such as in particular calcium formate
  • the carboxylic acid salt accelerator may react in situ with the untreated rice husks by countering the polymeric and lignocellulosic material to increase the bond strength of the cement to the surface of the husks.
  • the rice husks in the presence of the calcium carboxylic acid salt wets well and forms strong bonds to the cement.
  • the husks appear as thin fibrous matted sheets which, with the assistance of the calcium carboxylic acid salt accelerant, are able to bond strongly in the hardened cement composition.
  • the high silica content of the rice husks is also thought to contribute to their ability to form strong bonds with the components of the mortar compositions once set, with the aid of the calcium carboxylic acid salt accelerator.
  • the mortar compositions are prepared by adding the ingredients in any preferred order and mixing typically by agitation, rotation or shaking. Typically different size lots may require modification to the addition and mixing steps as well known to those skilled in the art.
  • the mortar compositions were prepared by the general method described in Example 1. All amounts are shown as parts by weight.
  • the mortar compositions were prepared by the general method described in Example 1. All amounts are shown as parts by weight.
  • the mortar compositions were prepared by the general method described in Example 1. All amounts are shown as parts by weight.
  • Example 4B Blank Series BR. Series Aa without rice husks
  • the mortar compositions were prepared by the general method described in Example 1. All amounts are shown as parts by weight.
  • Example 4C Blank Sand Series BS. Series Aa with rice husks replaced by sand
  • the mortar compositions were prepared by the general method described in Example 1. All amounts are shown as parts by weight.
  • the mortar compositions of Series Av and Series Bv were mixed with water in a 2:1 ratio (compositiomwater) unless otherwise stated, whilst the mortar composition of Series C was mixed with water in a 2.9:1 ratio.
  • the compositions were mixed by mechanical agitation until a soft paste formed.
  • the wet mortar compositions were let stand for 10 minutes before being used to assemble two ceramic tiles with a 13 mm offset in accordance with Australian Standard 2358. Results shown indicate the shear bond strengths (MPa) for tiles allowed to dry for 7 days (7d), 14 days (14d) and dried for 7 days and immersed in water for 7 days (7/7d) in accordance with Australian standard AS 2358, sections 3.2-3.4.
  • Example 5 The results depicted in Example 5 above clearly show the utility and advantages of the untreated rice husk/calcium formate accelerator mortar compositions of the present invention.
  • the 7 day strengths, 14 day strengths and 7 day dry/7 day wet strengths are all very good to excellent across the range of rice husk-mortar compositions.
  • the mortar compositions of Series Aa and the Blank Series BR were mixed with water in a 2:1 ratio (composition: water) unless otherwise stated, whilst the compositions of the Blank Sand Series BS were mixed with water in a 3:1 ratio.
  • Sets of ceramic tiles were assembled with the wet mortar compositions of Series Aa, BR and BS as described in Example 5. Results shown indicate the shear bond strengths (MPa) for tiles allowed to dry for 7 days (7d), 14 days (14d) and dried for 7 days and immersed in water for 7 days (7/7d) in accordance with Australian standard AS 2358, sections 3.2-3.4.
  • Example 6 The results depicted in Example 6 above clearly show the utility and advantages of the untreated rice husk/accelerator mortar compositions of the present invention.
  • Blank sand series BSO is a typical sand/cement mortar composition which exhibits excellent tensile and sheer strength when tested to AS 2358.
  • untreated rice husks series code AaO - i.e. no accelerator
  • Untreated rice husks clearly act as a retardant.
  • the blank series BR corresponds to the rice husk accelerator series Aa, but where the rice husks are not present and are not replaced by any other filler, such as sand. It can be seen from series BRO that omission of the retarding rice husks from series AaO allows for an increase in the strength of the mortar composition, approaching but not to the level of the full sand series BSO.
  • carboxylic acid salts such as sodium formate (series Aa5 and Aa6), calcium formate (series AalO, A and Aal), ammonium formate (series Aa7) and calcium acetate (series Aa8).
  • the strength imparted by calcium acetate is most surprising given that it is not considered an accelerator for cement.
  • the addition of calcium acetate causes retardation of the mortar strength at 14 days and 7/7 days when compared to the mortar composition without accelerator (series BSO).
  • carboxylic acid salts are able to compensate for the retardation caused by the untreated rice husks is most unexpected.
  • the mortar compositions of Series Ap were prepared with water in a 2:1 ratio (composition: water). Sets of ceramic tiles were assembled with the wet mortar compositions of Series Ap as described in Example 5. Results shown indicate the shear bond strengths (MPa) for tiles allowed to dry for 7 days (7d), 14 days (14d) and dried for 7 days and immersed in water for 7 days (7/7d) in accordance with Australian standard AS 2358, sections 3.2-3.4.
  • Example 8 shows variations in powder polymers wliich may be used in untreated rice husk mortar compositions of the invention whilst maintaining excellent bond strengths.
  • Example 9 Series Ah. Rice husks variation in formula A
  • the mortar compositions were prepared by the general method described in Example 1. All amounts are shown as parts by weight.
  • the mortar compositions of series Ah were mixed with water in the indicated ratio (composition: water).
  • Sets of ceramic tiles were assembled with the wet mortar compositions of series Ah as described in Example 5. Results shown indicate the shear bond strengths (MPa) for tiles allowed to dry for 7 days (7d), 14 days (14d) and dried for 7 days and immersed in water for 7 days (7/7d) in accordance with Australian standard AS 2358, sections 3.2-3.4.
  • Example 10 shows variations in the quantity of rice husks which may be used in the mortar compositions of the invention whilst maintaining acceptable bond strengths.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Botany (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention concerne une composition de mortier comprenant 100 parties en poids de ciment ; 1 à 80 parties en poids d'enveloppes de riz non traitées; 30 à 200 parties en poids d'une ou plusieurs charges et d'un ou plusieurs additifs ; 0,2 à 10 parties en poids d'un accélérateur. L'invention concerne également une composition de mortier durcissable et des procédés de production desdites compositions de mortier.
PCT/AU2001/000852 2000-07-14 2001-07-13 Composition de mortier et procede de production correspondant Ceased WO2002006182A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU2001272205A AU2001272205B2 (en) 2000-07-14 2001-07-13 Mortar composition and method
AU7220501A AU7220501A (en) 2000-07-14 2001-07-13 Mortar composition and method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPQ8790A AUPQ879000A0 (en) 2000-07-14 2000-07-14 Mortar composition and method
AUPQ8790 2000-07-14

Publications (1)

Publication Number Publication Date
WO2002006182A1 true WO2002006182A1 (fr) 2002-01-24

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AU (1) AUPQ879000A0 (fr)
WO (1) WO2002006182A1 (fr)

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WO2004037742A1 (fr) * 2002-10-28 2004-05-06 Fnr Forschungsgenossenschaft Nachwachsender Rohstoffe Procede pour fabriquer un materiau de construction a base vegetale et materiau de construction resultant de ce procede
WO2004071987A1 (fr) * 2003-02-17 2004-08-26 Greenbuild Group Materiaux de construction faits de dechets et procede de production de ces materiaux
WO2005070118A2 (fr) 2004-01-12 2005-08-04 United States Gypsum Company Revetements renforçateurs de surface pour sous-couches de sols a base de platre
WO2006037187A1 (fr) * 2004-10-08 2006-04-13 E.I.F.S. Holdings Limited Mélanges de cimentation améliorés
WO2007056805A1 (fr) * 2005-11-15 2007-05-24 Michael Albert Anderson Panneaux de construction et melanges cimentaires pour panneaux de construction
CN100413819C (zh) * 2006-06-30 2008-08-27 安徽理工大学 煤矿许用低爆速水胶炸药及其制造方法
EP1494660A4 (fr) * 2002-04-16 2009-06-03 Krosigk James Richard Von Composiiton et procede de lutte contre des champignons produisant des spores et contre des bacteries
EP2159258A1 (fr) * 2008-08-26 2010-03-03 Omya Development AG Produits de remplissage à base de minerai traité, leur procédé de préparation et leurs utilisations
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RU2470891C2 (ru) * 2011-04-08 2012-12-27 Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Самарский государственный архитектурно-строительный университет" (СГАСУ) Штукатурная сухая смесь для декоративной отделки фасадов зданий
RU2470902C1 (ru) * 2011-04-14 2012-12-27 Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Самарский государственный архитектурно-строительный университет" (СГАСУ) Штукатурная минеральная смесь для отделки фасадов зданий
ITMI20111301A1 (it) * 2011-07-13 2013-01-14 Buzzi & Buzzi S R L Materiale ad elevate prestazioni meccaniche e suo impiego nel settore dell'edilizia, dell'illuminazione e dell'arredamento
EP2567947A3 (fr) * 2011-09-06 2013-06-19 Fels-Werke GmbH Emballage de mortier à la chaux
CN103664100A (zh) * 2013-11-26 2014-03-26 蚌埠市天网渔需用品有限公司 一种微膨胀无机保温砂浆
ES2457277R1 (es) * 2012-01-23 2014-05-16 Fundación Centro De Innovación Y Desarrollo Tecnológico Mp panel
CN104016650A (zh) * 2014-05-30 2014-09-03 取卓材料科技(上海)有限公司 一种硅基地板及其制备方法
CN104072056A (zh) * 2014-05-23 2014-10-01 安徽阜阳思科达科技建材有限公司 防火保温砂浆
CN104177001A (zh) * 2014-07-18 2014-12-03 房晓磊 密质混凝土板材及其制造方法
CN104446611A (zh) * 2014-11-12 2015-03-25 安徽福来缘建材有限公司 一种绝热吸声加气砖及其制备方法
WO2015067588A1 (fr) 2013-11-05 2015-05-14 Yara International Asa Accélérateur de prise pour un mélange de mortier sec, processus de production d'un tel accélérateur de prise, mélange de mortier sec et pâte de mortier
CN104744013A (zh) * 2015-03-10 2015-07-01 柳州市郊区古灵第三砖厂 一种页岩清水墙砖
CN105503094A (zh) * 2016-01-14 2016-04-20 南通铁跃建材科技有限公司 硅粉在耐腐蚀保温板抹面抗裂砂浆中的应用
EP2647608A4 (fr) * 2010-12-01 2016-06-22 Urbanizaciones Inmobiliarias Del Ct S A De C V Matière composée à base d'écorce de riz et de liant modifié avec des nanostructures de carbone
WO2017087545A1 (fr) * 2015-11-19 2017-05-26 Sbc Group Llc Mélange, matériau pouvant s'écouler, matériau durci et procédé pour leur fabrication
CN107129228A (zh) * 2017-05-09 2017-09-05 安徽梦谷纤维材料科技有限公司 一种内墙应用的透气饰面砂浆
CN107721290A (zh) * 2017-11-27 2018-02-23 倪修俊 一种防水防火的小麦秸秆‑聚苯颗粒复合的保温砂浆及其制备方法
CN108706895A (zh) * 2018-05-25 2018-10-26 裴泽民 一种防渗透气沙的制备方法
CN109336487A (zh) * 2018-11-15 2019-02-15 肥西县创玺建材科技有限公司 一种新型建筑用保温砂浆
RU2681716C1 (ru) * 2018-02-05 2019-03-12 Общество с ограниченной ответственностью "ЛУКОЙЛ - Западная Сибирь" Тампонажный раствор для цементирования нефтяных и газовых скважин
CN111099853A (zh) * 2019-07-15 2020-05-05 海南瑞宸新型建材有限公司 一种新型砂浆添加剂及其制备方法
CN111492238A (zh) * 2018-01-03 2020-08-04 美国石膏公司 具有络合染料的接合化合物和灰泥及方法
EP3778522A1 (fr) * 2019-08-13 2021-02-17 RiceHouse srl Système et procédé de production de matériaux de construction écologiques
CN112707707A (zh) * 2019-12-20 2021-04-27 科之杰新材料集团有限公司 一种利用磨细玻璃粉生产的蒸压加气混凝土砌块及其制备方法
CN114230285A (zh) * 2021-12-29 2022-03-25 山东汇富建设集团有限公司 一种装配式绿色建筑保温墙体结构及其装配方法
WO2022246525A1 (fr) * 2021-05-25 2022-12-01 Moshe 3000 Materiais De Construção Ltda Procédé de fabrication et composition d'additif pour béton
CN115557761A (zh) * 2022-10-11 2023-01-03 浙江帝耐美环保科技有限公司 一种抗裂地面结构及其制备方法
CN115611586A (zh) * 2022-11-01 2023-01-17 浙江帝耐美环保科技有限公司 一种保温隔声楼面结构及其制备方法
CN116063040A (zh) * 2022-12-15 2023-05-05 贵州省鑫瀚蓝环保科技有限公司 一种抗裂抹面砂浆及其制备方法
CN116969743A (zh) * 2023-09-22 2023-10-31 高密市东泰建材有限公司 装修专用瓷砖铺装干粉砂浆料及其制备方法
CN117209220A (zh) * 2023-07-26 2023-12-12 江西中材新材料有限公司 一种发泡陶瓷安装用预拌砂浆及使用方法
HRP20230459A1 (hr) * 2023-05-10 2024-11-22 Dean Pavić Toplinsko izolacijska smjesa
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EP1494660A4 (fr) * 2002-04-16 2009-06-03 Krosigk James Richard Von Composiiton et procede de lutte contre des champignons produisant des spores et contre des bacteries
US8070877B2 (en) 2002-10-28 2011-12-06 Nawaro Ag Method for the production of a plant-based construction material and construction material obtained by means of said method
CN100354226C (zh) * 2002-10-28 2007-12-12 纳瓦罗股份公司 植物基建筑材料，该材料的制造方法和由该建筑材料制造的结构单元
WO2004037742A1 (fr) * 2002-10-28 2004-05-06 Fnr Forschungsgenossenschaft Nachwachsender Rohstoffe Procede pour fabriquer un materiau de construction a base vegetale et materiau de construction resultant de ce procede
WO2004071987A1 (fr) * 2003-02-17 2004-08-26 Greenbuild Group Materiaux de construction faits de dechets et procede de production de ces materiaux
WO2005070118A2 (fr) 2004-01-12 2005-08-04 United States Gypsum Company Revetements renforçateurs de surface pour sous-couches de sols a base de platre
EP1704046A4 (fr) * 2004-01-12 2009-06-03 United States Gypsum Co Revetements renforcateurs de surface pour sous-couches de sols a base de platre
WO2006037187A1 (fr) * 2004-10-08 2006-04-13 E.I.F.S. Holdings Limited Mélanges de cimentation améliorés
WO2007056805A1 (fr) * 2005-11-15 2007-05-24 Michael Albert Anderson Panneaux de construction et melanges cimentaires pour panneaux de construction
CN100413819C (zh) * 2006-06-30 2008-08-27 安徽理工大学 煤矿许用低爆速水胶炸药及其制造方法
WO2010023144A1 (fr) * 2008-08-26 2010-03-04 Omya Development Ag Produits de charge minérale traitée, procédé pour leur préparation et leurs utilisations
CN102131853A (zh) * 2008-08-26 2011-07-20 Omya发展股份公司 处理过的矿物填料产品、其制备方法及其用途
EP2159258A1 (fr) * 2008-08-26 2010-03-03 Omya Development AG Produits de remplissage à base de minerai traité, leur procédé de préparation et leurs utilisations
CN101973754A (zh) * 2010-10-26 2011-02-16 山东大学 一种用于浅层封堵的速凝注浆材料
EP2647608A4 (fr) * 2010-12-01 2016-06-22 Urbanizaciones Inmobiliarias Del Ct S A De C V Matière composée à base d'écorce de riz et de liant modifié avec des nanostructures de carbone
RU2470891C2 (ru) * 2011-04-08 2012-12-27 Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Самарский государственный архитектурно-строительный университет" (СГАСУ) Штукатурная сухая смесь для декоративной отделки фасадов зданий
RU2470902C1 (ru) * 2011-04-14 2012-12-27 Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Самарский государственный архитектурно-строительный университет" (СГАСУ) Штукатурная минеральная смесь для отделки фасадов зданий
ITMI20111301A1 (it) * 2011-07-13 2013-01-14 Buzzi & Buzzi S R L Materiale ad elevate prestazioni meccaniche e suo impiego nel settore dell'edilizia, dell'illuminazione e dell'arredamento
WO2013008118A1 (fr) * 2011-07-13 2013-01-17 BUZZI & BUZZI S.r.l. Matériau à haute performance mécanique et son utilisation dans le domaine de la construction, de l'éclairage et de l'ameublement
EP2567947A3 (fr) * 2011-09-06 2013-06-19 Fels-Werke GmbH Emballage de mortier à la chaux
ES2457277R1 (es) * 2012-01-23 2014-05-16 Fundación Centro De Innovación Y Desarrollo Tecnológico Mp panel
WO2015067588A1 (fr) 2013-11-05 2015-05-14 Yara International Asa Accélérateur de prise pour un mélange de mortier sec, processus de production d'un tel accélérateur de prise, mélange de mortier sec et pâte de mortier
US9611176B2 (en) 2013-11-05 2017-04-04 Yara International Asa Setting accelerator for a dry mortar blend, process for producing such a setting accelerator, a dry mortar blend and a mortar paste
CN103664100A (zh) * 2013-11-26 2014-03-26 蚌埠市天网渔需用品有限公司 一种微膨胀无机保温砂浆
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US10280117B2 (en) 2015-11-19 2019-05-07 Sbc Group Llc Admixture, flowable material, hardened material, and method of making the same
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CN107129228A (zh) * 2017-05-09 2017-09-05 安徽梦谷纤维材料科技有限公司 一种内墙应用的透气饰面砂浆
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RU2681716C1 (ru) * 2018-02-05 2019-03-12 Общество с ограниченной ответственностью "ЛУКОЙЛ - Западная Сибирь" Тампонажный раствор для цементирования нефтяных и газовых скважин
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EP3778522A1 (fr) * 2019-08-13 2021-02-17 RiceHouse srl Système et procédé de production de matériaux de construction écologiques
CN112707707A (zh) * 2019-12-20 2021-04-27 科之杰新材料集团有限公司 一种利用磨细玻璃粉生产的蒸压加气混凝土砌块及其制备方法
WO2022246525A1 (fr) * 2021-05-25 2022-12-01 Moshe 3000 Materiais De Construção Ltda Procédé de fabrication et composition d'additif pour béton
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CN115557761A (zh) * 2022-10-11 2023-01-03 浙江帝耐美环保科技有限公司 一种抗裂地面结构及其制备方法
CN115557761B (zh) * 2022-10-11 2023-11-21 浙江帝耐美环保科技有限公司 一种抗裂地面结构及其制备方法
CN115611586A (zh) * 2022-11-01 2023-01-17 浙江帝耐美环保科技有限公司 一种保温隔声楼面结构及其制备方法
CN115611586B (zh) * 2022-11-01 2023-11-21 浙江帝耐美环保科技有限公司 一种保温隔声楼面结构及其制备方法
CN116063040A (zh) * 2022-12-15 2023-05-05 贵州省鑫瀚蓝环保科技有限公司 一种抗裂抹面砂浆及其制备方法
HRP20230459A1 (hr) * 2023-05-10 2024-11-22 Dean Pavić Toplinsko izolacijska smjesa
CN117209220A (zh) * 2023-07-26 2023-12-12 江西中材新材料有限公司 一种发泡陶瓷安装用预拌砂浆及使用方法
CN116969743A (zh) * 2023-09-22 2023-10-31 高密市东泰建材有限公司 装修专用瓷砖铺装干粉砂浆料及其制备方法
CN116969743B (zh) * 2023-09-22 2023-12-05 高密市东泰建材有限公司 装修专用瓷砖铺装干粉砂浆料及其制备方法
EP4628468A1 (fr) * 2024-04-05 2025-10-08 Cuadern Campanals Arquitectes, S.L.P. Matériau de construction, produit de construction et procédé d'obtention de produits de construction

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