DE19735063A1 - Coated aggregate production for use in constructional concrete - Google Patents

Abstract

A coated aggregate for constructional concrete is produced by application, onto the particle surfaces of round or broken aggregate, of a compact and dense coating of cement, concrete additives and/or concrete additions as well as other auxiliary materials, the coating being thinner than the particle diameter. An Independent claim is also included for an apparatus used to carry out the above process, in which the coating is applied by accretion using a granulating disc, drum, cone or fluidised bed, an agglomerating press, a micro-encapsulation device or a mixed agglomeration device in the form of a trough, screw or free fall mixer.

Description

Construction concrete is characterized by high strength and good durability. Here comes as a concrete surcharge a mixture of broken or unbroken, equal to or different sized grains, natural or artificial Origin used, which in special cases also made of metal or consists of organic substances. In the national and international standards are included between the concrete surcharge dense structure and concrete aggregate with porous structure distinguished.

The most common is in structural engineering Concrete aggregate with a dense structure used with the suitable concrete recipe high strength and a favorable Durability can be achieved. But the prerequisite is that the fresh concrete has good cohesiveness and is so processable that it has no essential Demixing promoted, at the installation site even with more dense Reinforcement arrangement introduced and practically complete can be compressed. The processability of the fresh concrete depends on the concrete composition, especially on Water content of the concrete, of any additives used, of the fineness and quantity of fine substances as well as of type and Grain composition of the concrete aggregate. The behavior of the  hardened structural concrete is affected by the properties of the Concrete surcharge and the hydrated cement stone. Characteristic of the mechanical properties of the concrete is that the unloaded normal concrete in the contact zone has micro cracks between cement stone and aggregate. The Formation of the microcracks can affect the obstruction of the Shrinkage of the cement block due to the volume stable Surcharges from a dense structure can be reduced. Because of the low bond strength begin with a load on the Concrete in the amount of about 40% of the compressive strength already existing cracks to grow. The concrete strength is at a further increase in load is achieved as soon as the microcracks assume critical length. Hence, for strength and the fracture behavior of the concretes the bond strength shared responsibility between surcharge and cement stone.

In addition to aggregate from dense structure also takes place in concrete construction Supplement with porous structure use, which is usually a has significantly lower grain density and primarily for Manufacture of lightweight construction concrete is used. Structural lightweight lightweight concrete is characterized by technically advantageous usable properties (high Thermal insulation effect, low bulk density and favorable ratio from compressive strength to bulk density) that this building material numerous possible uses in structural engineering Offer. For a few years now, efforts have also been made to use high-strength lightweight concrete in civil engineering because of the smaller compared to normal concrete Construction weights combined with high strength considerable savings in prestressing and reinforcing steels becomes possible. In addition, the effort in formwork construction can be significant be reduced. Even the little effort involved in setting up a company of structures made of lightweight concrete as a result of the reduction in Construction weight can result in significant cost savings to lead.

In addition to the higher costs for the light aggregates, the however due to the reduced weight of the  Construction lightweight concrete through savings required reinforcing steel, with the required Foundation measures and the transport made therefrom Components can be compensated for, especially those considerable difficulties in processing the fresh concrete to name the use of lightweight, lightweight concrete in limit constructive civil engineering. Due to that Water absorption capacity of the open-pored light aggregates occurs during the mixing, conveying and installation of the lightweight concrete a change in the fresh concrete consistency. Withdrawal of parts of the mixing water is when pumping with concrete pumps particularly significant, since in addition to the capillary forces A large part of the mixing water is pumped into the pores of the pump Presses in light supplements.

To avoid the change in consistency, the Light surcharges in the course of the production of the fresh concrete mostly wet. The aim of the surcharges, Absorbing mixing water into their pore structure. However, with this procedure the Water cement value no longer exactly define how it especially with regard to the highest possible strength of the Structural lightweight concrete would be required. Can he pre-wet lightweight concrete on the construction site in the crane bucket are still conveyed to the installation site in a satisfactory manner, pumping the fresh concrete has not been possible so far. Due to the delivery pressures that occur during pumping (up to 50 bar, with a larger delivery range and heights, possibly even significantly higher pressures) during the dwell time of the Fresh concrete in the pump line (approx. 1 minute) Mixing water of the fresh concrete almost completely into the Open-pore lightweight aggregates pressed in. Blockages in the Pump line system and segregation of fresh concrete are the consequence.

The use of broken surcharges from the dismantling of buildings. Here large amounts of mineral rubble accumulate  has so far been deposited to a large extent and only to a small extent Scope again for subordinate construction tasks finds. A recycling of broken supplements Demolition material for the production of construction concrete has so far been restricted to individual cases, as the broken ones Aggregate materials are at least partially porous Have structure that the same as the light aggregates Extract fresh concrete from the mixing water. The Water absorption efforts of the demolition materials have an effect analogous to the light supplements, unfavorable on the fresh and Hardened concrete properties.

Already in the leaflets on manufacturing and processing of lightweight concrete in 1974 (Leaflets II and III for Lightweight concrete and lightweight steel concrete with a closed structure. In: Beton 24 H. 7, pp. 268-269 and H. 8, pp. 297-302, 1974) was on the problems of pumping lightweight concrete pointed out. With regard to the temporal, spatial and Economic benefits of this technology have been since then Various attempts have been made to solve these problems eliminate (summary presentation of the status of Technology up to 1975 by B. Schulz: Experience at Pumping lightweight concrete. In: Beton 25 H. 3, pp. 86/91, 1975).

So u. a. the grain surface of expanded clay aggregates Burn over with a glassy, waterproof layer Mistake. However, this process is hardly procedural to control and also leads to strong sticking of the Surcharges among themselves. The coating with Plastic dispersions also turned out to be little usable because on the one hand the bad connection and on the other hand, the damage and falling of the Envelopes during the handling of the supplements too controllable enrichments of plastic sleeves in the Lead lightweight construction concrete. The impregnation or The high aggregates could be made hydrophobic Moisture absorption of the lightweight concrete during exposure to the Do not counteract the pump delivery pressure. Alone a water  Presaturation of the light aggregates leads to lower ones Demixing of fresh concrete. But through the Water absorption of the light aggregates significantly higher bulk densities of fresh concrete and initially of hardened concrete. Next the loss of the beneficial thermal insulation effect must therefore significantly higher component weights are expected. Even in from the association of light aggregates manufacturers published information for manufacturing and processing of lightweight, lightweight concrete in structural engineering So far there are no indications to improve the Pump promotion (e.g. review by H. Schnabel; J. Spitzner: Structural lightweight concrete and lightweight steel concrete. In: Precast Concrete Technology 1992. S. Smeplass; A. Hammer; M. Sandvik: Production of Structural High Strength LWAC with Initially Dry Aggregates. In: Conference proceedings of Light concrete symposium in Sandefjord, Norway, 1995).

All of the measures known so far do not lead to either the desired improvement in the moisture behavior of the Surcharges and / or they are difficult from a procedural point of view feasible and / or they are uneconomical, d. H. she would lead to increased manufacturing costs, the amount not economically due to the technical advantages achieved can be compensated.

This also applies in connection with those from the patent literature known lightweight concrete aggregates or coated Surcharges.

From DD-PS 208 142 is a process for the production of Lightweight concrete components are known, according to the using the agglomeration of granules from lignite ash, Water and optionally cement are produced. The The granules are coated with cement - however by powdering and it should be readily apparent that in this way not a thin, compact and dense layer no sensible wrapping of the supplements for use in Structural concrete can be made.  

DE 26 23 378 A1 describes a method for pretreatment of a concrete / lightweight concrete aggregate disclosed, according to the a coating of aggregates with a cement-bound Layer is verified by specifying additives. The Process is characterized by the following features: It is based on an ordinary free-fall mixer, with which from no compact, sealed casing can be realized in advance can. A high water cement level is required in order to to allow a good homogenization of the mixture, with which but then a relatively low bond strength and a low strength and tightness of the casing is. The general rule is that suitable in free-fall mixers Envelopes with regard to layer thickness, composition and Tightness without further technological development and Installation of additional baffle plates etc. not with the required properties can be realized.

FR 2 664 262 A1 discloses the production of a Light aggregate from wooden raw materials of different sizes (for example sawdust, sawdust and Pieces of bark). The previously preserved ones wooden ingredients in a mixer in a thin liquid Sludges entered. The dispersed in the mixing water Cement particles adhere to the wooden surfaces and stick after the hydration of the cement particles smaller particles with the wood shavings and pieces of bark, so that a low-strength lightweight aggregate is created.

The object of the present invention is a method and a device for wrapping aggregates from dense and porous structure and thus to create surcharges per se with which the aforementioned disadvantages are avoided and with the production of structural concrete for civil engineering is made possible with aggregates made of porous structure, which as Bulk building material can be used and improved Ensure the properties of fresh and hardened concrete. In addition can concretes from open-pore aggregates, in particular  highly porous light aggregates, so that in future on the construction site can be promoted with customary concrete pumps.

The solution to this problem is through the features of Characterized claims.

The cement-bound covering according to the invention inhibits or on the one hand prevents the intrusion of the Mixing water in the pore structure of light aggregates as well of open-pore recycling surcharges and promotes another the bond between the grain surface of the aggregate and the surrounding fine mortar matrix. On the one hand, this is the advantage hand in hand that the fresh concrete neither when mixing nor during transport to the construction site, neither when conveying and pumping on the construction site when it is being inserted into the formwork larger amounts of mixing water by capillary suction or due to the pressure from the open-pore aggregates be withdrawn. This allows the fresh concrete to separate be prevented. The fresh concrete properties of the encased open-pore aggregates Construction concretes therefore correspond to those of Fresh concrete from normal supplements. The for Construction concrete from normal supplements known relationship between water cement value and concrete strength etc. largely also on structure-sealed lightweight concrete as well Concrete from recycling surcharges are transferred. As well concrete admixtures also have their effect Emphasize from porous aggregates in the same way as this is known from normal concrete. Requirements of Construction industry to a site-compatible and pumpable Fresh concrete can be encased through the use of open-pore aggregates are met. Through the Wrapping also increases the strength of a hardened Construction concrete from open-pore aggregates. By default a specifically adjustable water cement value consequently, high-strength even with coated light aggregates Construction lightweight concrete can be manufactured.  

Construction concrete from aggregate with a porous structure can thus easily for the creation of all engineering structures, for example of high-rise buildings, halls, bridges, off-shore Constructions, find use as the sealing cement-bound cladding is economical on the one hand Promotion of fresh concrete without affecting the Fresh concrete properties enables and on the other hand the Compliance with a defined bulk density in the fresh and ensures hardened condition and targeted strength, which is just for the planning and static dimensioning of Engineering structures should be known and predictable.

With the wrapping of aggregates you can still numerous other concrete properties can be improved.

The low water absorption capacity of enveloped open-pore aggregates the fire behavior of the Concrete is clearly different from a similar type of concrete Unwrapped surcharges are improved. That of the uncovered open-pore aggregates during mixing up mixing water absorbed to stiffen the fresh concrete can after hardening of the cement mortar matrix due to the dense matrix is only slowly released to the environment become. In the event of a fire, this leads to the open-pore surcharges water to high steam pressures, the blasting and cause flaking in the outer component layers. There with the wrapping according to the invention Water absorption efforts of the supplement are opposed, the fire protection of the construction concrete can be clearly be improved.

Wrapping the surcharges does not only do one Sealing the grain surface, but can also bond between the aggregate and the cement mortar matrix. So is from scientific microstructure studies known that the contact zone between normal surcharge and Cement block consists of a multi-layer system. Directly  a dense 2-3 µm thick adheres to the aggregate surface Calcium hydroxide contact layer. One closes above dense, 5-10 µm thick intermediate layer, which by a void-rich structure is characterized. Next tabular calcium hydroxide crystals and acicular Ettringite crystals can also be found here Calcium silicate hydrate. The big calcium hydroxide crystals have grown together with the contact zone. The intermediate layer points in the areas above, in the so-called Transition area with a thickness of 5-10 µm, a Structural compaction from calcium silicate hydrate and Calcium hydroxide. Here the structure of the Intermediate layer more and more the structure of the cement stone more like.

According to the microstructure of the composite area of Aggregate and concrete matrix is the biggest weak point of the Systems in the area of the contact zone, in which due to the The cement stone then strives to shrink during the Hardening form microcracks that trigger another Crack growth when the concrete is loaded and thus the Determine the strength and fracture behavior of the concrete. With the wrapping of supplements according to the invention can Training of the contact zone of the surcharge, however, considerably to be influenced. Hilsdorf and Ziegeldorf were already able to do this (Influence of the aggregate contact zones on the mechanical Properties of concrete, institute for concrete construction and Building materials technology, University of Karlsruhe, 1978) find that with a plastic dispersion modified cement block an increase in Contact zone strength can be achieved, which too leads to an increase in the strength of the concrete. With the inventive method for wrapping aggregates with dense and porous structure can all possible additives that have a positive effect on the contact zone strength, be used, the improvement aimed at the direct grain surface of the aggregate can be limited and thus a good bond between aggregate and wrapping  ensures. By adding suitable Plastic dispersions can consequently also the contact zone of the Targeted bond area between grain surface and coating be optimized. An optimal bond between wrapping and cement mortar matrix is characterized by the high Post-hardening potential of the cement-bound coating at Contact with the mixing water of the fresh concrete reached.

The method according to the invention is not only based on Coating or coating of cement-bound substances limited. It is also possible to use other materials, in particular to apply metals, color pigments, etc. allow concrete with special properties to manufacture the additional uses of supplements allowed from dense or porous structure. For example through the use of thermally conductive additives at Wrapping the lightweight aggregate a lightweight concrete with good Thermal conductivity can be created, in particular as Screed in underfloor heating would offer great advantages. By adding electrically conductive additives to the Wrapping aggregates from dense and porous structure can also an electrostatically suitable floor screed, for example for electrotechnical and chemical Industry. Generally all of them can Additives are included in the wrapper with which the properties of a concrete can be influenced favorably can.

Starting materials are used to encase the concrete aggregates used, a mixture of cements, concrete admixtures and / or concrete additives that are identical and therefore completely compatible with those in the production of concrete used materials of the concrete matrix. The consequence of this is an improved bond behavior between aggregate and mortar matrix of the concrete, so that a cheaper Strength and fracture behavior of the coated aggregates manufactured concrete can be achieved.  

Another advantage is that the Wrapping process a smaller amount of water is used, than for the full hydration of the for wrapping cement is needed. Therefore, the Wrapping over a post-hardening potential that one optimal association between wrapped light aggregate and Ensures cement mortar matrix of the concrete. It can also the bond in the contact zone of the grain surface of the Surcharge and the cement-bound coating layer Adding suitable substances during the wrapping process considerably compared to the normal combination of aggregate and cement mortar be improved. Previous investigations on lightweight concrete already led to an increase in compressive strength more than 30% compared to a lightweight concrete of the same Mix composition, but with uncoated Aggregates. Even with concretes from aggregates with dense Structures can increase strength through an improvement the bond zone between the grain surface and Cement mortar matrix can be achieved. In addition, the queues up microcracking of the grain surface in the concrete along the grain boundaries to a much lesser extent, if an enveloped surcharge using Plastic dispersions are used that at a more favorable strength behavior of the construction concrete leads.

The covering or coating preferably consists of Cements and concrete admixtures and / or concrete admixtures.

The essence of the invention can ultimately be seen in the fact that Starting materials of the coating only with suitable Process techniques in a minimal layer thickness, be built evenly and compactly on the aggregate can have a sufficient sealing effect and a improved bond between aggregate and mortar matrix of the To achieve concrete. As suitable and economical Process engineering for wrapping according to the invention is available currently mainly the built-up agglomeration with the  Granulating plate or the granulating drum, if necessary, that Granulating fluidized bed process, available in which the Supplements are first wet and then the Coating by evenly adding the cement water is sprayed simultaneously. With a The granulating fluidized bed process can be developed further even this technology is economical for a uniform use a dense and thin layer of aggregates. Other processes, such as the use of press agglomeration, the Microencapsulation and mixed agglomeration in the Free fall mixer or with the screw mixer, can not in accordance with the current state of the art be used in a suitable and economical manner in order to controls the wrapping of the supplements according to the invention build up. Especially with the last two methods mentioned either the aggregates must be prewetted intensively, to then add the finely dispersed starting materials to apply in the mixer to the aggregate. The addition is made of cement in the form of a slurry, they remain for the Wrapping materials used only unevenly and not adhere compactly to the grain surface. The requirements for a tight wrapping according to the invention are therefore not Fulfills.

Since the casing according to the invention can be applied economically to the grain surface in a technically simple and manageable form at the present time with the build-up agglomeration with a granulating plate or a granulating drum, the procedural steps for coating the aggregates from a dense and porous structure are shown below using this technology:
First, the batches or continuously introduced in the granulating plate or in the granulating drum on the inclined plate surface are subjected to a constant rolling movement. During this rolling movement, the finely dispersed solids, ie the cement, the concrete admixtures, the concrete admixtures and possibly other auxiliaries are coated or coated uniformly thinly with simultaneous spraying with a binder liquid, preferably water. The uniform addition of cement with further addition of liquid prevents the formation of conglomerates from coated aggregate grains. Favorable coatings can be achieved by adding water and cement in a mass ratio of water to cement of about 1: 4. The optimal ratio is determined by the type of cement used and the concrete admixtures or concrete admixtures.

Depending on the desired improvement of the concrete properties in the fresh or solid state can be various Concrete admixtures and additives as well as others Auxiliaries are added individually or in combination, the optimal components and Addition quantities have to be worked out.

Above all, there are concrete additives Concrete plasticizers, plasticizers, stabilizers, Concrete sealant, solidification accelerator and possibly Air entraining agents available. The concrete admixtures are added only in relatively small amounts. Usually they have to be mixed into the water to ensure that the Grain surfaces can be distributed. Both it is physically active concrete admixtures mostly surface-active substances, which in addition to a liquefying effect by reducing the Surface tension of the water also a foam or Can trigger air pore formation. As a surface active In addition to anion-active substances, there are also cation-active substances Fabrics for use. Furthermore, noniogenic substances used. The influences of the individual concrete admixtures the coating process and the properties of the coated Surcharges and the concrete made from them are in To investigate preliminary tests.  

Concrete additives are finely divided substances that pass through chemical or physical effects Concrete properties, e.g. B. consistency, processability, Affect the strength, tightness or color of the casing. Inert substances, for example quartz or stone powder Limestone, could be used to control the percentage of cement in the wrapper and thus reduce costs. Pigments can be used to color the surcharges. Pozzolanic substances that contain a high amount of silica and optionally have clay, can with water and Calcium hydroxide, which is formed when the cement hardens, react. These additives could therefore be used to increase the post-hardening potential of the coating increase and the type and duration of aftercare of the to control the enveloped surcharge. Common pozzolans are Hard coal fly ash, silica dust or silicate Fine dust and tempered stone powder. In addition to the special Influences on the strength development of the Wrapping layer affects pozzolans as a result of their small particle diameter also favorable in terms of Packing density of cement and concrete additives from because the smaller particles into the cavities of the larger ones Store cement grains. Since they are next to the cements the much greater delicacy also partly spherical Having shape increases the addition of, for example Silicatic fine dust affects the adhesive effect of the coating the grain surface, which is not in the case of built-up agglomeration is absolutely necessary, which is particularly the case with a Coating in the granulating fluidized bed process is advantageous can impact. Latent hydraulic substances similar to those pozzolanic substances combined with an exciter, for example calcium hydroxide, but do not react deal with the stimulator itself, for example blastfurnace slag or blast furnace slag, could also be used to to control the post-hardening potential of the casing.

Other auxiliaries are plastic dispersions or others organic substances, for example high-performance  Polymers or cellulose used as plasticizers or Acting stabilizer, the stickiness or packing density can affect the wrapping. They can also Auxiliaries depending on the type and composition also one more favorable strength development, an increase in Deformability or an increase in Wear behavior of the coating cause. Furthermore can also use plastic dispersions to optimize the Find after-treatment.

Spherical supplements, such as. B. natural gravel or in Construction lightweight concrete mostly used expanded clay granules can be coated particularly well. With the Agglomeration in the granulation plate or in the Granulating drum can also be broken, angular Cover aggregate with a barrier layer. However, it should be noted that this is larger Amounts of cement are required and the layer thickness of the Wrapping more uneven compared to spherical aggregates becomes. For broken materials, the use of To aim for granulating fluidized bed process, which also broken grain shapes with a coating according to the invention can be coated.

After the coating has hardened by the reaction of the Cement with the water used for the coating a surcharge is then available, which is the previous one listed improvements in processability the fresh concrete but also the properties of the hardened Ensures concrete.

The wrapping process can be central to the Surcharge manufacturers take place, as well as just before of concrete production. Will be wrapping the concrete aggregates made at the contract manufacturer, for example in Connection to wet dredging and grading gravel, according to breaking and classifying natural or recycled Starting materials, after firing expanded clay, etc., the  coated aggregate are treated sufficiently so that the wrapping one for storage, handling and the necessary strength achieved later mixing process. The Art and the duration of the aftercare must be different subsequent storage of the coated aggregate (silo or Stockpile storage) and on the loads by overlying orientated additional masses, in the case of a still not fully hardened coating a conglomeration to avoid the enveloped surcharges. Shall the enveloped Supplements are stored outdoors, it must be taken into account that by weathering the properties of the casing be affected as the precipitates another reaction of the not yet fully hydrated cement. However, further hydration has no adverse consequences for the enveloped surcharge itself. However, the bond should between the coated aggregate and the cement mortar matrix of the concrete would be optimized, however, would be a storage of the Prefer surcharges in the silo or a covered hall, the post-hardening potential of the coated aggregate to be able to fully use.

Alternatively, the envelope can also be decentrally direct before concrete production. This would require special Cements and concrete admixtures are used that the Accelerate the reaction process of the cement in the coating, so that immediately or shortly after leaving the Granulating plates, the granulating drum or the The pelletizing fluid bed system has an adequate coating Has strength so as not to get damaged when mixing and also have a sufficient sealing effect to demonstrate the required workability and Ensures that the fresh concrete is pumpable. By the Suitable cements and concrete admixtures can be used the wrapping according to the invention immediately before Produce concrete production without problems. In form of a technical expansion of the concrete mixing plant the factory wrapping is currently still the less economical variant of the wrapping process.  

But there should be enveloped supplements on the market establish, for example, enveloped light supplements for Structural lightweight concrete, encased recycling surcharges for Construction concrete or even encased aggregates made of dense Structure to increase the strength and to improve the Durability by minimizing the micro cracks in the Concrete, represents the direct upstream of the Coating process prior to concrete production interesting technological perspective also for the Ready-mixed concrete industry.

The invention is explained in more detail below with the aid of several examples:
The light aggregate grains are placed on the inclined plate surface of the granulating plate (instead of a granulating plate, a granulating drum can easily be used or even the granulating fluidized bed method can be used) and initially slightly prewetted in order to cause the cement to adhere to the light aggregate grain surface. After sufficient pre-wetting, the grains in rolling motion are coated by evenly adding the cement while spraying water. The water spraying should preferably take place in the movement paths of the smaller aggregate grains. The total amount of water supplied during the coating process should not exceed a ratio of the added cement of 0.3 in order to avoid conglomerations of the aggregates. In addition, the cement cannot fully hydrate during the coating process. During the subsequent hardening of the structure-sealed lightweight concrete, a subsequent hardening of the cement applied for the covering can be achieved, which can bring about an improvement in the bond between the aggregate and the covering and also between the covering and the fine mortar matrix of the concrete. With the method according to the invention, with the use of cement, a conventional commercial stabilizer and water, a coating could be achieved which, compared to the uncoated light aggregate grain, with a one-minute pressurization of 50 bar instead of 37.1% water by weight, only 5.3% by weight. Absorbs water. The strength of the concrete made from this coated lightweight aggregate reaches an increase of more than 30% at the age of 28 days compared to the strength of the lightweight concrete made from untreated lightweight aggregate. Further improvements can be expected when optimizing the wrapping.

The aim of the invention is to wrap the aggregate from dense and porous structure to the workability of the fresh concrete and / or the properties of the hardened concrete Use enveloped supplements to significantly improve. The wrapper essentially comes with a moisture barrier Effect and / or an improvement in the bond behavior, the covering being made of a uniformly dense layer is to build up, with a minimum layer thickness in the sense a reduction in costs and a reduction in bulk density in the case of light surcharges is to be aimed for.

The following concrete aggregates can be used with the invention Wrapping are provided and achieve improvements the fresh and hardened concrete properties, too examples are:

Surcharges with dense structure:
The coating of aggregates with a dense structure can lead to a significant increase in the concrete strength and thus influences the fracture behavior of the concrete.
Grain shapes: spherical and angular, broken
Types of aggregates: quartzite, dense and other limestone, quartzitic and other sandstone, basalt, porphyry, granite, blast furnace slag etc.

Due to the coating surrounding the grain can for Construction concrete with all types of aggregates sufficient strength to be used due to  otherwise only rarely in Use structural concretes.

Supplements with a porous structure are e.g. B. Light supplements and Demolition materials.

The coating of light aggregates solves the previous problems of workability and pumpability of lightweight construction concrete. In addition, the behavior of the hardened concrete can be favorably achieved through the targeted observance of the water cement value and the fresh concrete consistency.
Grain shapes: spherical and angular, broken
Surcharge types: expanded clay, natural pumice, broken lava slag, boiler slag, sintered pumice, expanded slate, expanded glass etc.

With the covering of demolition materials, surcharges can be won not only from the demolition of concrete structures, but also from the rubble from the demolition of normal buildings. A variety of different mineral building materials from masonry construction as well as from ceilings, floors and roofs arise here.
Grain shapes: angular, broken
Types of material: demolition of concrete (normal surcharge with mortar matrix), brick chippings, masonry mortar, plasters, screeds, building materials such as earthenware / fine ceramic tiles, stoneware, roof tiles, bricks from sand-lime brick, bricks, aerated concrete, pumice concrete, expanded clay concrete etc.

Other starting materials can be used to optimize the Covering according to the invention are used.

In addition to the commercially available cements and special binders, a wide variety of concrete additives and / or concrete additives can also be used to optimize the properties of the coating according to the invention (sealing effect even at high pump pressures, good bond between grain and coating, high post-hardening potential, shelf life, wear properties, fire behavior, conductivity etc.) as well as other concrete auxiliaries are used. A wide variety of combinations of starting materials can be used, which are to be selected depending on the type of improvement to be made to the concrete due to the coated aggregate:
Cements: All customary cements and all special binders.
Concrete admixtures: concrete plasticizers (BV); Plasticizers (BV), air entraining agents (LP), sealants (DM), accelerators (BE), stabilizers (ST) etc.
Concrete additives: inert substances (quartz and limestone powders), color pigments, pozzolans (tress, hard coal fly ash, silica fume, silicate fine dust, tempered rock dust, fly ash), latent hydraulic substances (slag sand), heat-conducting and electrically conductive substances etc.
other auxiliaries: plastic dispersions, high-performance polymers, cellulose, fibers etc.

Basically, for the inventive wrapping of Supplements to build agglomeration and that Granulating fluidized bed method suitable to a possible to build up a thin coating on the grain surface that due to the uniform and compact arrangement of the finely dispersed materials achieve a high level of tightness. The Build-up granulation offers various options to build up the coating according to the invention on the grain surface. In addition to the pelletizing plate and the pelletizing drum a so-called pelletizing cone can also be used. Next the pelletizing cone is a one-step process multilevel continuously or gradually graded  Plate areas so that different layers on the Grain surface can be built, the individual Layers composed of different materials could be. In the pelletizing plate or in the pelletizing drum baffle plates etc. can also be installed in order to Uniformity of the coating and the packing density of the to optimize substances in the wrapping. In addition to the usual rotationally symmetrical walls could also be polygonal Plate and drum walls are used. Furthermore, the rolling motion and thus the Layer structure of the coated aggregate can be influenced. The build-up agglomeration in the granulating plate, in the Granulating drum and in the granulating cone as well Granulating fluidized bed process can be carried out in batches as well as operate continuously.

Press agglomeration process, such as in the pharmaceutical industry for the production of tablets are known, could in a further development of the Procedure and with a careful and narrow classification the grain sizes of the surcharge to be coated as well Find use. Here are the surfaces of the Double cylinder press rolls according to the grain sizes of the structured surcharge structured. The wrapping is consequently pressed onto the grain surface of the aggregate. Theoretically microencapsulation would also be a technical possibility, Surcharges on the surface with a coating too Mistake. Here electrostatic charges are used, around the finely dispersed particles on the aggregate surface the coating and water as a binding liquid. The mixed agglomeration in the form of an ordinary Free fall mixer is largely excluded. Only if the raw materials in a largely dry form in the mixer available and by means of baffle plates and other internals in the Mixing vessel a compression of the finely dispersed substances on the Grain surface can take place, u. A useful one Wrapping can be applied to the surcharge. Trough mixer, Screw mixers etc. may also offer  Starting points in order to further develop the Procedures in large quantities covered supplements with the to produce properties according to the invention.

The wrapping of the supplements according to the invention can be done with the Process techniques listed above either centrally at the manufacturer of the aggregates themselves, i.e. in the gravel works in After the classification, in the crusher or after Burning process after cooling the raw aggregate respectively. The surcharge can be taken directly from the Production line or be picked up from the stockpile.

Another possibility is decentralized wrapping of the surcharges immediately before the actual Concrete production, for example in the ready-mixed concrete plant or on the site. To the sealing effect and a sufficient strength in the coated layer if possible to reach early, so that the wrapped surcharge is not required, in addition to quickly hardening cements or special binders too Concrete admixtures in the form of solidification accelerators be added.

With regard to the efficiency of the invention Procedure should be noted that at the current state of the Technology with the help of the build-up agglomeration in the granulation plate or in a pelletizing drum a coating with a uniform layer thickness, with a uniform on the covering the entire surface without leaks and one compared to the diameter of the aggregate thin layer thickness is best possible. The thin-layer coating causes in particular Slight increases only a slight increase in the bulk density of light supplements. Nevertheless, the layer thickness is sufficient due to the blocking effect of the wrapping a withdrawal of large parts of the mixing water even at high pressures  to face. The construction agglomeration in one Granulation plate or in a granulation drum allows straight with round supplements a particularly compact and therefore build up a sealing layer on the grain surface. Also in the case of broken aggregates, the sealing effect can be reduced the cement-bound cladding with the build-up agglomeration in Reach the pelletizing plate or in the pelletizing drum. To just take into account that due to the broken, angular grain shape of the demolition material a more uneven Layer than when wrapping spherical aggregates is built up. Improvements can be made here with the more complex but manageable granulating fluidized bed process achieve, where even angular supplements with an extreme thin layer can be wrapped.

Claims (10)

1. A process for producing a coated aggregate for structural concrete, the coating being built up from cements, concrete admixtures and / or concrete admixtures and other auxiliaries, characterized in that a compact and dense coating is applied to the grain surface of the round or broken aggregate, the thinner than the grain diameter is. 2. The method according to claim 1, characterized in that the coating is carried out by means of built-up agglomeration by

• - the aggregates are prewetted first, and
• - The coating is done by evenly adding the cement while spraying water.

3. The method according to claim 1 or 2, characterized in that a light aggregate with open-pore as aggregate Structure is used (e.g. expanded clay, natural pumice, broken lava slag, sintered pumice, expanded slate, Expanded glass etc.), which is sealed with the covering and thus as lightweight construction concrete in the form of Fresh concrete has a constant workability and Ensures pumpability and predictable Fresh concrete bulk densities in the fresh and solid state as well as a defined concrete strength. 4. The method according to claim 1 or 2, characterized in that as a surcharge a recyclate from dismantling materials with open-pored structure is used (for example  Demolition of concrete, brick chippings, masonry mortar, plasters, screeds, building materials, roof tiles, bricks Lime sandstone, brick, aerated concrete, pumice concrete, expanded concrete etc.), which is sealed with the covering and thus in Can be used in conjunction with construction concrete which in the form of fresh concrete is constant Ensures processability and pumpability and predictable fresh concrete bulk densities in fresh and solid Have a state as well as a defined one Concrete strength. 5. The method according to claim 1 or 2, characterized in that as an aggregate an aggregate with a dense structure is used (e.g. quartzite, limestone, Sandstone, basalt, porphyry, granite etc.), which means that with the Wrapping a significant increase in bond strength between aggregate and cement mortar matrix of the concrete is achieved. 6. The method according to any one of claims 1 to 5, characterized characterized in that to optimize the wrapping in addition commercially available cements also special binders be used. 7. The method according to any one of claims 1 to 5, characterized characterized that to optimize the wrapping with regard to tightness, layer thickness and Composite strength in addition to various cements Concrete admixtures (concrete plasticizers, plasticizers, Air entraining agents, sealants, accelerators, Stabilizers etc.) and / or concrete additives (inert Fabrics, color pigments, pozzolans, latent hydraulic Substances etc.) and / or other auxiliary substances (Plastic dispersions, high-performance polymers, cellulose, Fibers etc.) are used. 8. The method according to any one of claims 1 to 5 or 7, characterized characterized in that also electrically in the enclosure  conductive (metal powder, graphite etc.) and / or heat-conducting substances (metal powder etc.) integrated become. 9. The method according to any one of claims 1 to 8, characterized characterized that the wrapping of the supplements directly after winning or producing the surcharges (after dredging, breaking, burning, etc.) or immediately before concrete production (e.g. in Ready-mixed concrete plant). 10. Device for performing the method according to one of the Claims 1 to 9, characterized in that for Coating through build-up agglomeration of a granulating plate or a pelletizing drum or a pelletizing cone or a granulating fluidized bed device or one Press agglomeration device or one Microencapsulation device or one Mixed agglomeration facility in the form of a trough or Screw or free fall mixer is provided.