RU2846877C1 - Insulating plate and method of its production - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: group of inventions relates to the field of construction, namely to the building structures heat-insulating elements, and can be used in production as a filler for sandwich panels when making walls, heat-insulating material on building facades and roofs, a warm plate when pouring a foundation or when making a roadway. Insulating plate is made from a composition containing binder in form of cement mortar with an adhesive additive and filler in form of foamed polystyrene granules, with the following ratio of components, wt. %: cement – 56-60; adhesive additive – 5-6; polystyrene granules – 5-6; water – balance. In order to make the board, mortar is filled with cement, foamed polystyrene granules are added, dry mass is mixed and hardening water is gradually added with addition of glue, the obtained mixture is placed into a casing, compacted with a press and cured under the press force. Then the formwork is stripped and the obtained products are unloaded. Cutting is carried out after stripping and curing.

EFFECT: production of insulation plate not subject to delamination of polystyrene and concrete granules, increased homogeneity of finished product at simultaneous increase of strength.

6 cl, 1 tbl, 8 ex

Description

The group of inventions relates to the field of construction, namely to heat-insulating elements of building structures, in particular to methods for manufacturing concrete products that use lightweight porous fillers and cement binders with additives, and can be used in production as a filler for sandwich panels in the construction of walls, heat-insulating material on the facades and roofs of buildings, and a warm slab when pouring a foundation or constructing a road surface.

A composition for the production of expanded polystyrene concrete, a method for its production and a monolithic block are known from the existing level of technology (Patent RU 2763568 C1, 08.07.2021, C04B 38/08, C04B 24/34, C04B 22/08, C04B 16/08, B28B 1/08, C04B 111/20, E04C 1/00). The composition for the production of expanded polystyrene concrete, including polystyrene granules, water, D0 (M500) grade cement, sand, characterized in that it additionally contains an aqueous solution of sodium silicate in a ratio of 1:10, as well as saponified wood resin in the form of a 10% aqueous solution, with the following ratio of components, wt.%:

polystyrene granules 2-3 cement grade D0 (M500) 69-72 sand 15-25 an aqueous solution of sodium silicate in a ratio of 1:10 1.8-2.5 saponified wood resin in the form of a 10% aqueous solution 1.2-1.6 water rest

A method for producing expanded polystyrene concrete, including loading polystyrene granules into a mechanical concrete mixer, adding water to the mixture, adding cement to the mixture and mixing until a homogeneous mass for 1 minute, adding sand to the mixture and mixing until a homogeneous mass for 1 minute, characterized in that after loading polystyrene granules into a mechanical concrete mixer and adding water, an aqueous solution of sodium silicate is additionally added to the mixture and mixed for 1-2 minutes, then saponified wood resin is added to the mixture, then, after preparing the mixture, pre-prepared molds with facade matrices placed on the bottom are filled, after which the filled molds are vibrated for 10-15 seconds, each mold is manually shaded to remove air bubbles from the walls of the finished product, the mixture is heated in molds in heating chambers for 1-2 hours to a temperature of 60-80 ° C, the finished material is cooled for 4-5 hours, the finished material is removed from the molds and treatment of the façade with a deep-penetrating primer, after which the finished material is packaged in polyethylene film and left to settle for 2 days.

A monolithic block manufactured in the described manner, and it is made with a gradient body density, with the highest density in the façade part and the lowest density in the rear part.

The disadvantage of this method is the complexity of production due to the use of autoclaves.

The closest technical solution selected as a prototype is a method for manufacturing a heat-insulating product (patent RU 2254310 C1, 18.12.2003, C04B 40/00, C04B 38/08), including the following operations: preparing a molding mixture from Portland cement, water and foamed polystyrene, molding and heat treatment of products, characterized in that Portland cement grade 400-500, granulated foamed polystyrene grade PVG with a bulk density of 10-20 kg/ ^m3 are used, microsilica and superplasticizer C-3 are additionally introduced into the molding mixture, and first the said Portland cement is mixed with microsilica and the said foamed PVG for 2-3 minutes, then water containing superplasticizer C-3 is added, mixed for 3-5 minutes, the mixture is loaded into molding boxes, carry out molding by vibration compaction and pressing, followed by removal of products from the molding boxes before heat treatment, which is carried out in the following mode: 2 hours at a temperature of 15-25°C, then 8 hours at 40-60°C and 1 hour at 15-30°C, with the following ratio of components, mass%:

the specified Portland cement 60.0-65.6 microsilica 6.6-12.0 specified PVG 2.2-4.4 superplasticizer C-3 0.6-0.66 water rest

The main disadvantage of the above-described technical solutions is the insufficient strength of the insulation boards during their manufacture; due to the mixing of polystyrene foam granules with cement mortar, stratification of the mixture occurs, which leads to non-uniform properties throughout the volume of the polystyrene concrete mixture.

The technical result of the claimed group of inventions is to ensure high-quality production of an insulating board that is not subject to delamination of polystyrene granules and concrete, with increased density (homogeneity) of the finished product while simultaneously increasing strength.

To achieve the specified technical result, a method for manufacturing an insulating plate and an insulating plate are proposed.

The insulating board is made from a composition containing a binder in the form of a cement mortar with an adhesive additive and a lightweight filler in the form of expanded polystyrene granules, wherein the composition contains the said components in the following ratio, mass%:

cement 56-60 adhesive additive 5-6 polystyrene granules 5-6 water rest

In particular, sand in an amount of 2-3% by weight can be added to the solution for the production of the mentioned slab.

In particular, to obtain a slab with a density of 100 kg/ ^m3, a composition of the following composition is prepared, kg:

cement – 80

silicate glue – 8

polystyrene granules – 8

water – 38

In particular, to obtain a slab with a density of 120 kg/ ^m3, a composition of the following composition is prepared, kg:

cement – 95

silicate glue – 9

polystyrene granules – 9

water – 51

In particular, to obtain a slab with a density of 140 kg/ ^m3, a composition of the following composition is prepared, kg:

cement – 115

silicate glue – 10

polystyrene granules – 10

sand – 5

water – 62

In particular, to obtain a slab with a density of 100 kg/ ^m3, a composition of the following composition is prepared:

cement – 80 kg

polyurethane glue – 8 kg

polystyrene granules – 8 kg

sand – 3 kg

water – 38 l

In particular, to obtain a slab with a density of 120 kg/ ^m3, a composition of the following composition is prepared:

cement – 95 kg

polyurethane glue – 9 kg

polystyrene granules – 9 kg

sand – 5 kg

water – 51 l

In particular, to obtain a slab with a density of 140 kg/ ^m3, a composition of the following composition is prepared:

cement – 115 kg

polyurethane glue – 10 kg

polystyrene granules – 10 kg

sand – 5 kg

water – 62 l

A method for producing insulating boards, characterized by adding expanded polystyrene granules to cement, mixing the dry mass, and gradually adding mixing water with adhesive to obtain a composition containing, in wt.%: cement 56-60, adhesive additive in the form of silicate or polyurethane adhesive 5-6, expanded polystyrene granules 5-6, water (the balance). The resulting mixture is placed in formwork, compacted with a press, and held under the press for curing. The formwork is removed and the resulting products are unloaded, and cutting is performed after removal and curing. The mixture is cured for 8 hours.

In addition, the strength gain is achieved within 10-12 hours.

Moreover, from the beginning of the mixture preparation, including hardening under the press, gaining strength, and finishing cutting, the process of obtaining the finished product takes from 20 to 24 hours.

The quality and technical characteristics of insulation boards are influenced by many factors, one of which is the quality of the materials used to produce the desired product. For example, the storage conditions of cement affect its strength. Excessive moisture disrupts the chemical composition of the material and degrades its properties. For example, after one calendar month, M500 Portland cement loses its strength characteristics and matches the properties of M400 cement, while after one calendar year, the material is unsuitable for construction work. Both the additives and composition used, as well as the production technology, can mitigate any material quality deficiencies.

As a result of the practical selection of component masses and preparation technology, it was possible to achieve a result that meets the requirements for thermal insulation boards.

The effectiveness and efficiency of the proposed method for producing insulating boards are demonstrated by specific examples of implementation.

Example 1. Pour 80 kg of cement into a mortar mixer and add 8 kg of expanded polystyrene granules (PVG). Mix the dry mixture and gradually add 38 liters of mixing water, adding 8 kg of silicate adhesive. Mix the molding mixture until a homogeneous mixture is formed. Then, load the mixture into a molding box, compact it with a press, and hold it under the press for 8 hours to cure. Remove the molding blank from the molding box and store it in a warehouse to cure for 10 hours, then cut it into slabs.

The quantitative and time parameters of the following examples of preparation of insulating boards and tests are given in the table.

Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Composition and method of preparation of the mixture Cement, kg 80 95 115 115 80 95 115 115 Expanded polystyrene granules, kg 8 9 10 10 8 9 10 10 Water, l 38 51 62 62 38 51 62 62 Adhesive additive, kg Silicate glue 8 9 10 10 - - - - Polyurethane adhesive - - - - 8 9 10 10 Sand, kg - - 5 5 3 5 5 5 Curing time, hours 8 8 8 8 8 8 8 8 Strength gain holding time, hours 10 10 10 12 10 10 10 12 Characteristics of finished insulation boards Density, kg/ ^m3 100 kg/ ^m3 (+/-10%) 120 kg/ ^m3 (+/- 10%) 140 kg/ ^m3 (+/- 10%) 140 kg/ ^m3 (+/- 10%) 100 kg/ ^m3 (+/- 10%) 120 kg/ ^m3 (+/- 10%) 140 kg/ ^m3 (+/- 10%) 140 kg/ ^m3 (+/- 10%) Compressive strength, MPa 0.28 0.29 0.30 0.30 0.28 0.29 0.30 0.30 bending strength, MPa 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 Thermal conductivity coefficient, W/m⋅K 25±5°С – 0.046 25±5°С – 0.047 25±5°С – 0.048 25±5°С – 0.048 25±5°С – 0.046 25±5°С – 0.047 25±5°С – 0.048 25±5°С – 0.048 Water absorption under full immersion, % by volume 0.95 1.0 1.05 1.05 0.98 1.0 1.08 1.08 Tensile strength, MPa 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 Thickness, mm 50 50 50 50 50 50 50 50 Flammability group G-1 G-1 G-1 G-1 G-1 G-1 G-1 G-1

In example 1, laboratory tests conducted using silicate glue as an adhesive additive revealed the following qualitative and quantitative indicators: the resulting insulation boards had a density of 100 kg/ ^m3 (+/- 10%), compressive strength of 0.28 MPa, bending strength of 0.30 MPa, with a thickness of 50 mm, a thermal conductivity coefficient at 25±5°C of 0.046 W/(m⋅K), water absorption of no more than 0.95%, tensile strength of 0.11 MPa, flammability group G1.

In example 2, the insulating boards had a density of 120 kg/ ^m3 (+/- 10%), compressive strength of 0.29 MPa, with a thickness of 50 mm, a thermal conductivity coefficient at 25±5°C of 0.047 W/(m⋅K), water absorption of no more than 1.0%, other indicators remained unchanged.

In example 3, the insulating boards had a density of 140 kg/ ^m3 (+/- 10%), compressive strength of 0.30 MPa, with a thickness of 50 mm, a thermal conductivity coefficient at 25±5°C of 0.048 W/(m⋅K), water absorption of no more than 1.05%, other indicators remained unchanged.

In example 4, with the same composition as in the previous example, the indicators remained unchanged; an increase in the curing time to 12 hours had a slight effect on increasing the time for cutting the workpiece into slabs.

In example 5 and the following ones, when using polyurethane glue as an adhesive additive, the insulation boards had a density of 100 kg/ ^m3 (+/- 10%), compressive strength of 0.28 MPa, bending strength of 0.30 MPa, with a thickness of 50 mm, a thermal conductivity coefficient at 25±5°C of 0.046 W/(m⋅K), water absorption of no more than 0.95%, tensile strength of 0.11 MPa, and flammability group G1.

In example 6, the insulating boards had a density of 120 kg/ ^m3 (+/- 10%), compressive strength of 0.29 MPa, with a thickness of 50 mm, a thermal conductivity coefficient at 25±5°C of 0.047 W/(m⋅K), water absorption of no more than 1.0%, other indicators remained unchanged.

In example 7, the insulating boards had a density of 140 kg/ ^m3 (+/- 10%), compressive strength of 0.30 MPa, with a thickness of 50 mm, a thermal conductivity coefficient at 25±5°C of 0.048 W/(m⋅K), water absorption of no more than 1.05%, other indicators remained unchanged.

In example 8, increasing the curing time to 12 hours also slightly increased the time it took to cut the workpiece into slabs.

The given examples of tests have shown that the characteristics of the finished insulation boards have minor variations that do not have a significant impact on the overall composition, the composition and time characteristics of the method make it possible to achieve the stated technical result, an insulation board that is not subject to delamination of polystyrene granules and concrete, increased density (homogeneity) of the finished product while simultaneously increasing strength and obtaining thermal insulation boards that meet the requirements imposed on them.

The proposed group of inventions is used as follows: the components are loaded into a mechanical concrete mixer in the following ratio (by weight): 5-6% polystyrene granules, 56-60% cement, 5-6% adhesive additive, and the remainder water, and mixed until a homogeneous mass is formed. After the mixture is prepared, it is filled into pre-prepared molds. The filled molds are vibrated to remove air bubbles and compacted with a press. The mixture is then cured for 8 hours under the press. The mold is then disassembled, and the semi-finished block is stored in a warehouse to gain strength for 10-12 hours. It is then cut on a band saw to the required dimensions (blocks and slabs) and sent to a warehouse for final curing. In total, from the beginning of the mixture preparation, including curing under the press, gaining strength, and finishing cutting, the process of obtaining the finished product takes from 20 to 24 hours.

The implementation of the proposed method made it possible to achieve the following characteristics of the finished insulation boards:

density, kg/ ^m3 - 100-140 (+/- 10%)

compressive strength, MPa - 0.29

bending strength, MPa - 0.30

thermal conductivity coefficient, W/mK - 25±5°С – 0.047

water absorption upon complete immersion, % by volume -1.0

tensile strength, MPa - 0.11

thickness, mm - 50

flammability group - G-1

The stated technical result is achieved through the use of lightweight porous polystyrene granules (reduced weight and moisture absorption, increased heat and sound insulation, increased strength and resistance to deformation), while the sequence and duration of the mixing, vibration, and hardening processes specified in the method prevent the floating of polystyrene granules, ensure the density of the finished material, thereby significantly reducing material consumption, the cost of the finished product, and reducing the total time required for the production of the product.

Claims (7)

1. An insulating board made from a composition containing a binder in the form of a cement mortar with an adhesive additive and a lightweight filler in the form of expanded polystyrene granules, characterized in that the composition contains the said components in the following ratio, mass%: cement 56-60 adhesive additive 5-6 polystyrene granules 5-6 water rest 2. An insulating plate according to paragraph 1, characterized in that it is a heat-insulating plate. 3. A method for producing an insulating board, characterized by adding expanded polystyrene granules to cement, mixing the dry mass and gradually introducing mixing water with the addition of glue to it to obtain a composition containing, by weight: cement 56-60, adhesive additive in the form of silicate or polyurethane glue 5-6, expanded polystyrene granules 5-6, water - the rest, placing the resulting mixture in formwork, compacting with a press and maintaining it under the force of the press for hardening, stripping the formwork and unloading the resulting products, and cutting is carried out after stripping and strength gain. 4. The method according to paragraph 3, characterized in that the curing of the mixture is carried out for 8 hours. 5. The method according to paragraph 3, characterized in that the strength gain takes 10-12 hours. 6. The method according to paragraph 3, characterized in that from the beginning of the preparation of the mixture, including hardening under the press, gaining strength, and finishing cutting, the process of obtaining the finished product takes from 20 to 24 hours.