WO2017006237A1 - Composition de béton fibré (frc), son procédé de préparation et article frc - Google Patents

Composition de béton fibré (frc), son procédé de préparation et article frc Download PDF

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Publication number
WO2017006237A1
WO2017006237A1 PCT/IB2016/054003 IB2016054003W WO2017006237A1 WO 2017006237 A1 WO2017006237 A1 WO 2017006237A1 IB 2016054003 W IB2016054003 W IB 2016054003W WO 2017006237 A1 WO2017006237 A1 WO 2017006237A1
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WIPO (PCT)
Prior art keywords
range
composition
fiber reinforced
amount
reinforced cement
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.)
Ceased
Application number
PCT/IB2016/054003
Other languages
English (en)
Inventor
Sreekumar Thaliyil Veedu
Nilesh Shankar REVAGADE
Vikas Kadu Bhangale
Abhijit Vasantrao KASHETWAR
Rohit Verma
Arun Arora
Chandramouli Gangaram GAJELLI
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.)
Reliance Industries Ltd
Original Assignee
Reliance Industries Ltd
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 Reliance Industries Ltd filed Critical Reliance Industries Ltd
Publication of WO2017006237A1 publication Critical patent/WO2017006237A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • B28C5/40—Mixing specially adapted for preparing mixtures containing fibres
    • B28C5/404—Pre-treatment of fibres
    • B28C5/406—Pre-treatment of fibres and mixing with binding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
    • E04C5/073—Discrete reinforcing elements, e.g. fibres
    • 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 disclosure relates to a Fiber Reinforced Cement (FRC) composition, a process for preparing the same and articles prepared from that Fiber Reinforced Cement (FRC) composition.
  • FRC Fiber Reinforced Cement
  • Denier Denier is a unit for the measurement of linear mass density of fibers. It is defined as the mass in grams per 9000 meters.
  • Tenacity is the customary measure of strength of a fiber or yarn. It is expressed as grams per denier (gpd).
  • Fiber Elongation Fiber elongation is specified as the percentage of increase in length as compared to the initial length.
  • Uster value is the measurement of evenness, thick places, and thin places in a fiber.
  • Quenching It is a method used for rapid cooling of melt to obtain fibers.
  • Draw Ratio expressed as the ratio of cross sectional area of undrawn material to that of the drawn material.
  • MRA MR a refers to the modulus of rupture adjusted to the dry density of the cement specimen. MR A is directly proportional to the flexural strength of the cement specimen.
  • BACKGROUND Fibers are widely used as reinforcement material for Fiber Reinforced Cement (FRC) composites. Asbestos fibers are most commonly used as a reinforcement fiber in FRC. However, due to the carcinogenic effect of asbestos, the use of synthetic fibers as reinforcement material in FRC is progressively increasing, with an approach to minimize the use of asbestos fibers.
  • FRC Fiber Reinforced Cement
  • the bonding efficiency of fibers with the cement matrix is a prerequisite for selecting the fibers for such use. If the bonding of fibers with the cement matrix is poor, the FRC will have a low modulus of rupture, resulting in lower flexural strength of the FRC. Parameters affecting the bonding of fibers with cement include the cross section of the fiber, the length of the fiber and the surface of the fiber. Fibers known in the art, have a circular cross section. An FRC made from fibers having circular cross section, has inferior interaction between the fibers and the cement matrix and therefore shows inferior flexural strength, due to the lower area of contact between the fibers and the cement matrix.
  • the present disclosure provides a fiber reinforced cement composition.
  • the fiber reinforced cement composition of the present disclosure comprises polyester fibers having gear shaped cross section in an amount in the range of 0.05 to 5% with respect to the total mass of the composition. Further, the fiber reinforced cement composition comprises cement in an amount in the range of 30 to 60% with respect to the total mass of the composition.
  • the amount of asbestos fibers used in the fiber reinforced cement composition is less than 14% with respect to the total mass of the composition.
  • Pulp typically cellulosic pulp is used in an amount in the range of 0.5 to 5% with respect to the total mass of the composition.
  • the fiber reinforced cement composition further comprises at least one filler in an amount in the range of 30 to 50% with respect to the total mass of the composition.
  • polyester fiber having gear shaped cross section used in the fiber reinforced cement composition of the present disclosure, is characterized by:
  • the method of preparing the fiber reinforced cement composition of the present disclosure comprises the following steps:
  • the polyester, of the polyester fiber used in the fiber reinforced cement composition of the present disclosure can be at least one selected from the group consisting of polyethylene terephthalate (PET), polytrimethylene isophthalate (PTI), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polytrimethylene napthalate (PTN), polybutylene naphthalate (PBN), polyethylene naphthalate (PEN) and vectran.
  • the filler used in the fiber reinforced cement composition of the present disclosure can be at least one selected from the group consisting of fly ash, hard ground waste and a mixture of fly ash and hard ground waste. Further, the fiber reinforced cement composition of the present disclosure can be used to make various articles.
  • the article can be made by molding the fiber reinforced cement composition in a mold under pressure to obtain a molded mass followed by air curing the molded mass to form the article.
  • the articles made from the fiber reinforced cement composition of the present disclosure have density in the range of 1.25 to 1.40 gm/cm and an MR A in the range of 170 to 190 kg/cm 2 .
  • Figure 1 illustrates a block diagram of the process for manufacturing filaments having gear shaped cross section
  • Figure 2 illustrates a block diagram of the process for manufacturing staple fibers having gear shaped cross section
  • Figure 3 illustrates the gear shaped cross section of the fibers obtained from the process as shown in Figure 2 of the present disclosure.
  • Fiber reinforced cement (FRC) composites known in the art teach the use of fibers having lower surface area which reduces the bonding of fibers with the cement matrix.
  • the fiber reinforced cement (FRC) composite shows inferior flexural strength.
  • these fiber reinforced cement (FRC) composites contain asbestos fibers, which is carcinogenic to humans.
  • FRC composites having improved strength and environment friendly properties.
  • fiber reinforced cement composition for preparing articles.
  • the fiber reinforced cement composition of the present disclosure comprises polyester fibers having gear shaped cross section.
  • the amount of polyester fibers used in the fiber reinforced cement composition of the present disclosure is in the range of 0.05 to 5% with respect to the total mass of the fiber reinforced cement composition.
  • the fiber reinforced cement composition of the present disclosure comprises cement in an amount in the range of 30 to 60% with respect to the total mass of the fiber reinforced cement composition.
  • the cement used in the fiber reinforced cement composition of the present disclosure can be selected from the group consisting of Ordinary Portland Cement (OPC) and Pozzolanic Portland Cement (PPC).
  • the fiber reinforced cement composition comprises asbestos fibers in an amount less than 14% with respect to the total mass of the FRC composition.
  • the fiber reinforced cement composition of the present disclosure comprises pulp in an amount in the range of 0.5 to 5% with respect to the total mass of the fiber reinforced cement composition.
  • the pulp used in the fiber reinforced cement composition of the present disclosure is at least one selected from the group consisting of cellulosic pulp and textile fiber waste.
  • the fiber reinforced cement composition comprises at least one filler in an amount in the range of 30 to 50% with respect to the total mass of the composition.
  • the filler used in the fiber reinforced cement composition of the present disclosure is at least one selected from the group consisting of fly ash, hard ground waste and a mixture thereof.
  • Figure 1 depicts the process steps for the manufacturing of filaments having gear shaped cross section.
  • the polymer material is melted in an extruder (1) at a temperature in the range of 220 to 300 °C to obtain a molten mass.
  • the molten mass is passed through a spinneret (2) having multiple gear shaped holes, to obtain a plurality of filaments having gear shaped cross section.
  • the filaments coming out of the spinneret having gear shaped cross section are quenched in a quench air (3), at a temperature in the range of 20 to 25 °C.
  • the air flow rate used for quenching is in the range of 0.4 to 0.7 m/s, preferably 0.6 m/s.
  • the filaments coming out of the spinneret holes freeze instantly resulting in the filaments having uniform and similar cross section as that of the spinneret holes.
  • These filaments then passed through a finish oil applicator (4) followed by pig tail guide (5) and kiss roller (6).
  • the filaments thus obtained are passed through a series of godet rollers, godet roller- 1 (7 and 8) and godet roller-2 (9 and 10) for drawing.
  • the filaments After passing through the series of godet rollers, the filaments are wound on a spinning package at a speed in the range of 3500 to 4200 m/minute. A draw ratio in the range of 2 to 5 is used for drawing the filament. Further, these filaments are cut into required length and used in FRC composition.
  • Figure 2 depicts the process steps for manufacturing staple fibers having gear shaped cross section.
  • spinneret (11) is used to produce single tow of as-spun fiber.
  • the tow is collected in a can (14) followed by drawing the tow in drawing zone (15 and 16) for post spinning operation.
  • the tow is passed through an annealer zone (17).
  • the thus obtained tow is passed through a finish oil applicator where, a layer of oil is sprayed on the tow.
  • the tow is then passed through a crimper (19) to obtain crimped fibers. Crimping is done to impart bulkiness to the fibers.
  • crimped fibers are then passed through a cutter (20) to obtain staple fibers having gear shaped cross section as shown in Figure 3, which can be used in the preparation of articles.
  • a draw ratio in the range of 3 to 4 and a speed in the range of 150 to 180 m/minute are used for the staple fiber rout.
  • a process for preparing a fiber reinforced cement composition comprises the following steps:
  • Polyester fibers having gear shaped cross section are dispersed in water to obtain a dispersion of the polyester fibers in water.
  • a slurry, comprising pulp and water is prepared.
  • the slurry is then mixed with the dispersion to obtain a mixture.
  • cement containing asbestos fibers and at least one filler are added gradually with continuous stirring to obtain the fiber reinforced cement composition.
  • the polyester of the polyester fibers having gear shaped cross section, is at least one selected from the group consisting of polyethylene terephthalate (PET), polytrimethylene isophthalate (PTI), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polytrimethylene napthalate (PTN), polybutylene naphthalate (PBN), polyethylene naphthalate (PEN) and vectran.
  • PET polyethylene terephthalate
  • PTI polytrimethylene isophthalate
  • PBT polybutylene terephthalate
  • PTT polytrimethylene terephthalate
  • PBN polytrimethylene napthalate
  • PBN polybutylene naphthalate
  • PEN polyethylene naphthalate
  • vectran vectran
  • the article prepared from the fiber reinforced cement composition of the present disclosure includes sheets, columns, panels, slabs, shafts, boards, plinths, planks and tiles.
  • the article thus prepared comprises:
  • polyester fibers having gear shaped cross section in an amount in the range of 0.05 to
  • cement in an amount in the range of 30 to 60% by weight
  • the article prepared from the fiber reinforced cement composition of the present disclosure is an FRC sheet.
  • the process of preparing the FRC sheets comprises the following steps:
  • the fiber reinforced cement composition is introduced in a mold and pressed using a hydraulic press at a predetermined pressure to remove the moisture present in the composition. The same pressure is maintained for 1 minute and then the press is slowly removed.
  • the sheets thus obtained, are placed in 90% humidity for 24 hours followed by water curing the sheets by keeping the sheets in water for a predetermined time and then the sheets are air cured to obtain the ready to use FRC sheets.
  • the above process for the manufacturing of FRC sheets is based on laboratory scale. On industrial scale, the the FRC sheets are manufactured by Hatscheck process.
  • the fiber reinforced cement composition is used for the manufacturing of FRC sheets.
  • the process employs the use of a specific number of vats or containers and endless felt to form the layers of FRC sheets. Solids from the FRC composition get transfer from the vats to the felt to form the FRC sheets of specific thickness.
  • the FRC sheet made from the fiber reinforced cement composition of the present disclosure has density in the range of 1.25 to 1.4 gm/cm 3 and an MR A in the range of 170 to 190 kg/cm .
  • a quench air duct was maintained at a distance of 5 to 20 cm below the spinneret. Air at a flow rate of 0.6 m/s was blown and a temperature of 20 °C was maintained for quenching the filaments having gear shaped cross section. At this air flow rate and temperature, the filaments freeze and filaments of uniform gear shaped cross section as that of the spinneret holes, were obtained.
  • These filaments were then passed through a finish oil applicator followed by pig tail and a kiss roller. The filaments thus obtained were passed through a series of goddet rollers and wound on a spinning package at a speed of 3700 m/minute. A draw ratio of 2.3 was used for drawing the filaments.
  • the filaments from the spinning package were taken and passed through an annealer where the filaments were moderately heated. Further, the filaments were passed through a finish oil applicator to provide lubrication to the filaments. The lubricated filaments were passed through a crimper to obtain crimped filaments. A cutter was used to cut the crimped filaments and to obtain staple fibers having gear shaped cross section. A draw ratio of 3 and a speed in the range of 160 m/minute was used for the staple fiber rout. (lb) - Preparation of the Fiber Reinforced cement composition
  • the fiber reinforced cement composition obtained from Experiment 1 was used to make the FRC sheets.
  • the fiber reinforced cement composition was introduced in a mold and pressed till a pressure of 550 bar was reached, using a hydraulic press to remove the moisture present in the composition.
  • the pressure of 550 bar was maintained for 1 minute and then the press was slowly removed.
  • the sheets thus obtained, were placed at 90% humidity for 24 hours followed by keeping the sheets in water for 14 days for water curing and thereafter, the PRC sheets were air cured for 24 hours.
  • the FRC sheet made from the fiber reinforced cement composition of the present disclosure as given in Experiment 2 was compared with the FRC sheet containing conventional circular cross section PET fibers.
  • the amount of materials used in the preparation of FRC sheet from the fiber reinforced cement composition of the present disclosure and the FRC sheet made from the composition comprising conventional circular cross section PET fibers is shown here in Table 2 below.
  • PET fibers (having gear 0.7 —
  • PET fibers (having — 0.7
  • the MR A of the FRC sheet made from the fiber reinforced cement composition of the present disclosure was 171 kg/cm whereas the MR A of the FRC sheet made from the composition containing conventional circular cross section PET fibers was 145 kg/cm .
  • the FRC sheet comprising gear shaped PET fibers has an improvement of 18% in MR A over the FRC sheet containing conventional circular cross section PET fibers.
  • the FRC composition of the present disclosure comprises gear shaped PET fibers which have high surface area as compared to the circular cross section PET fibers, which results in improved bonding between the gear shaped PET fibers and the cement matrix and also higher friction between the fibers and the cement matrix.
  • the FRC sheet comprising gear shaped PET fibers has an improved MR A over the FRC sheet containing conventional circular cross section PET fibers.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Architecture (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

La présente divulgation concerne le domaine des compositions de béton fibré (FRC) pour préparer des articles. La composition FRC selon la présente divulgation comprend : i. des fibres polyester ayant une section transversale en forme d'engrenage en une quantité dans la plage de 0,05 à 5 %; ii. du ciment en une quantité dans la plage de 30 à 60 %; iii. des fibres d'amiante en une quantité inférieure à 14 %; iv. une pâte de cellulose en une quantité dans la plage de 0,5 à 5 %; et v. au moins une charge en une quantité dans la plage de 30 à 50 %. La composition FRC selon la présente divulgation utilise une quantité réduite de fibres d'amiante et les articles préparés à partir de la composition FRC selon la présente divulgation présentent des propriétés mécaniques améliorées.
PCT/IB2016/054003 2015-07-04 2016-07-04 Composition de béton fibré (frc), son procédé de préparation et article frc Ceased WO2017006237A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
IN31/MUM/2015 2015-07-04
IN31MU2015 2015-07-04
IN201622022815 2016-07-02
IN201622022815 2016-07-02

Publications (1)

Publication Number Publication Date
WO2017006237A1 true WO2017006237A1 (fr) 2017-01-12

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WO (1) WO2017006237A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2042607A (en) * 1979-02-09 1980-09-24 Amiantus Fibrereinforced hydraulically setting materials
US6753081B1 (en) * 2001-02-21 2004-06-22 Forta Corporation Fiber reinforcement material, products made therefrom, and method for making the same
US20100147194A1 (en) * 2005-10-17 2010-06-17 Concretos Translucidos, S. De R.L. De C.V. Formulation for Obtaining a Fibre-Reinforced Concrete Mixture with High Mechanical Strength and Low Volume Weight

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2042607A (en) * 1979-02-09 1980-09-24 Amiantus Fibrereinforced hydraulically setting materials
US6753081B1 (en) * 2001-02-21 2004-06-22 Forta Corporation Fiber reinforcement material, products made therefrom, and method for making the same
US20100147194A1 (en) * 2005-10-17 2010-06-17 Concretos Translucidos, S. De R.L. De C.V. Formulation for Obtaining a Fibre-Reinforced Concrete Mixture with High Mechanical Strength and Low Volume Weight

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