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WO2014064635A1 - Produit cimentaire à usage ornemental non structurel - Google Patents

Produit cimentaire à usage ornemental non structurel Download PDF

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Publication number
WO2014064635A1
WO2014064635A1 PCT/IB2013/059610 IB2013059610W WO2014064635A1 WO 2014064635 A1 WO2014064635 A1 WO 2014064635A1 IB 2013059610 W IB2013059610 W IB 2013059610W WO 2014064635 A1 WO2014064635 A1 WO 2014064635A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
product according
cementitious product
cementitious
insert
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/IB2013/059610
Other languages
English (en)
Inventor
Roberta Alfani
Giuseppe MANGANELLI
Flavio RAMPINELLI
Michele DE LONGIS
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.)
Italcementi SpA
Original Assignee
Italcementi SpA
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 Italcementi SpA filed Critical Italcementi SpA
Priority to EP13820895.4A priority Critical patent/EP2911847A1/fr
Publication of WO2014064635A1 publication Critical patent/WO2014064635A1/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
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0056—Means for inserting the elements into the mould or supporting them in the mould
    • 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
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0075—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects for decorative purposes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/80—Optical properties, e.g. transparency or reflexibility

Definitions

  • Object of the present invention is a cementitious product for ornamental, non- structural use, in particular for applications with aesthetic and decorative purposes in integrated architecture.
  • Patent application PCT/EP2012/067762 by the same Applicant describes cementitious products having a thin thickness, particularly in plate form, with controlled surface curvature and roughness, produced by mould casting of a fluid composition comprising a hydraulic binder, one or more aggregates, an anti- shrinkage agent, a superfluidifying agent and water.
  • the mould consists of two half-moulds which internal surface is at least partly or completely coated with a material selected from polyethylene terephthalate, polycarbonate, polyamide, polymethylmethacrylate, or other similar material capable of imparting low surface roughness to the cementitious product during the casting step.
  • the present invention proposes a cementitious product for non-structural ornamental use, such as a plate or a panel, characterized in that it is produced by mould casting a fluid composition comprising:
  • the face of the insert that was fixed against the mould to form a seal is thus free and visible, therefore appearing as a marquetry on the surface of the product. Since the insert can have a shape, design, colour of marked aesthetic effect that varies within an unlimited range, the cementitious product thus produced is indicated for decorative, even customisable architecture.
  • non-absorbent plastic materials such as polymethylmethacrylate, fluorescent polymethylmethacrylate, or glass, metal, stone, minerals, cementitious products and/or derivatives thereof, or even materials that are as such hydrophilic, e.g. cardboard or wood, nevertheless treated in such a way as to make them completely water-repellent for the aims of the invention and provided with sufficient rigidity and non-deformability to
  • such inserts can be made by automatic computer aided cutting via laser, water-based tools, milling cutters and the like, with a view to obtaining greater cutting precision and to producing even elaborate ornamental motifs.
  • a metal casting mould of the type that has horizontal walls for cementitious applications is used.
  • a metal casting mould of the type that has vertical walls consisting of two die-halves is used.
  • the mould is previously prepared by fixing at least one ornamental insert in hydrophobic material, for example plastic, onto the internal wall of at least one of the two die- halves to form a seal by means of a secure but removable fixing system, so as to allow ease of removal, at the end, of the cementitious finished product that incorporates the insert.
  • the fastening system is produced by magnetic coupling for example, or by means of a non-water absorbent adhesive film, or by surface tension by applying a suitable fluid to the insert-mould interface in question, such as for example a silicone oil, or other suitable systems.
  • this surface must be snug-sealed onto the internal wall of the mould onto which it is fixed so as not to allow the fluid composition to seep onto the surface during casting, thus covering and ruining the decorative effect sought.
  • the fixing agent for example, a film of bi-adhesive material
  • the insert to the mould does not protrude beyond the face or surface of the insert which should be visible, a circumstance that could cause points of discontinuity in the casting and therefore lack of adhesion of the insert-cementitious material interface in the finished product.
  • the insert having been thus fixed to the mould, there is casting of a fluid composition
  • a fluid composition comprising a hydraulic binder, one or more aggregates, an anti- shrinkage agent, a superfluidifying agent and water, thus producing a mortar characterized by high fluidity, self-levelling properties, without segregation phenomena, minimal hygrometric shrinkage, reduced air content within the mixture.
  • the composition is capable of pouring and filling the mould in an ideal way, and of coupling with the insert embedded therein, incorporating it once hardened, giving a final product with controlled curvature and free of deformations, wherein at the end said insert is visible on the surface of the product as a ornamental marquetry.
  • a metal casting mould of the type that has horizontal or vertical walls for cementitious applications is used.
  • the mould consists of two half-moulds which internal surface is partly or completely coated with a material selected from polyethylene terephthalate, polycarbonate, polyamide, polymethylmethacrylate, or other similar material capable of imparting a high surface finish to the cementitious product during the casting step, in order to obtain a surface of the cementitious product that is characterized by a low surface roughness. No further finishing treatment such as sanding or polishing is thus required.
  • a normal mould is used to form the cementitious products, without any special requirements in relation to surface roughness.
  • the product is obtained by mould casting while applying a vibrating ancillary motion.
  • Further variant embodiments provide for the fixing of ornamental inserts in hydrophobic material to both the opposite internal walls of the mould to obtain a final cementitious product with visible insert on both faces of the plate or panel thus produced, or to fix several inserts onto the same face of the mould.
  • Hydraulic binder means a powdered material in the solid dry state which, when mixed with water, provides plastic mixtures that are capable of setting and hardening, even underwater, such as cement.
  • a clinker usable for preparing a binder for the present invention is any common cement clinker, as defined according to UNI EN 197.1 standard, i.e. a hydraulic material with at least two- thirds in mass consisting of calcium silicates (3CaO*SiO 2 ) and (2CaO*Si0 2 ), the remaining part being AI2O3, Fe 2 0 3 and other oxides; for example a Portland cement clinker.
  • hydraulic binder also comprises white, grey or pigmented cements defined according to the aforementioned UNI EN 197.1 standard, as well as the so-called cements for retention structures, cementitious agglomerates and hydraulic limes as defined in Italian law no. 595 of 26 May 1965 and inorganic silicates.
  • calcium sulphoaluminate- based binders can be used, such as the compounds described in patents and/or patent applications WO2006/18569, EP-A-1306356 and EP-A-018 739, and those deriving from the calcium sulphoaluminate clinkers described in the "Green Chemistry for sustainable cement production and use” review by John W. Phair Green Chem., 2006, 8, 763-780, in particular in chapter 5.3 on page 776, as well as the calcium sulphoaluminate clinkers described in the article, "Calcium sulfoaluminates cements-low energy cements, special cements" J. H.
  • aluminous, sulpho-ferroaluminous cements as described in Advances in Cement Research, 1999, 11 , No. 1 , Jan. 15-21 , can also be suitably used.
  • photocatalytic cements i.e. binders having photocatalytic action obtained by adding to the composition a photocatalyst capable of oxidising the organic and inorganic pollutants present in the environment, in the presence of light, air and environmental humidity.
  • the photocatalyst can be selected from each compound capable of oxidising the pollutants that come into contact with the surface of the cementitious compositions in the hardened state, in the presence of light, oxygen and water.
  • the preferred photocatalyst according to the present invention is titanium oxide or a precursor thereof, and more typically titanium oxide at least partially in the form of anatase.
  • titanium oxide at least partially in the form of anatase means that at least 5%, preferably 25%, more preferably at least 50%, still more preferably in at least 70% of the titanium oxide particles have an anatase structure, as percentages by weight on the total weight of the titanium oxide.
  • Examples of photocatalytic cements are the products in the TX range (Italcementi), such as TX Area®, TX Air®.
  • a preferred form of the invention uses Italcementi sulpho-aluminous Alipre® Cement, Italcementi Portland Ultracem® 52.5R cement, Italcementi Italbianco® 52.5 cement and Italcementi cement TX Area® cement as binder.
  • composition for producing a product according to the present invention can also optionally comprise anhydrite or gypsum.
  • the aggregates also known as inert aggregates, according to the present invention can include:
  • filler means a fraction of fine aggregate having maximum diameter d ma x, equal to 40 microns;
  • the aggregates can be suitably selected from limestone, quartz or silico- calcareous aggregates in any form, or crushed, or spherical aggregates, for example marble powders, ceramic finish marble and even marble that has been lightened to reduce the final weight of the product.
  • the relative percentage amount of aggregates having different dimensions is optimised to give the mortar rheological characteristics suitable for mould casting, in particular high fluidity, prolonged machinability for the time necessary for casting, and absence of segregation phenomena prior to hardening, while safeguarding the final mechanical properties of the hardened product.
  • Some aggregates as in the case of coloured marble powders, also have an aesthetic function; more specifically, the can confer special colour characteristics and nuances or veining. to the product by reproducing the appearance of natural stones.
  • the composition can also optionally contain one or more ancillary substances common in the field, such as mineral or pozzolanic fillers, organic and/or inorganic pigments or the like.
  • Mineral or pozzolanic fillers means microsilica, silica fume, slag, fly ash, metakaolin, natural pozzolanas, natural limestones and precipitated calcium carbonate.
  • the starting cementitious composition must contain at least one agent or anti-shrinkage additive that is capable of reducing hygrometric shrinkage, in liquid or solid phase.
  • agents or anti-shrinkage additive that is capable of reducing hygrometric shrinkage, in liquid or solid phase.
  • SRAs shrinkage reducing agents
  • Lime in the form of oxide, can be added in combination therewith.
  • glycols, diols and polyols or mixtures thereof or glycol ethers, derivatives and mixtures thereof are used as anti-shrinkage additives III.
  • the commercial product, Cimparement, a liquid additive consisting of a mixture of synthetic polymers and ethers, albeit classified as an antifoam product has anti- shrinkage properties.
  • the cementitious starting composition must contain at least one superfluidifying agent or additive, preferably of the polycarboxylic type, added in either solid phase or in the form of an aqueous solution.
  • at least one superfluidifying agent or additive preferably of the polycarboxylic type, added in either solid phase or in the form of an aqueous solution.
  • polycarboxylic superfluidifying agents selected from the product Melflux 2641 F in solid form, or the product Glenium 71 SCC (modified polycarboxylate ether) or Driver 72 of Axim in liquid form are employed.
  • Water-binder ratio means the ratio of the total amount of water used in the composition's formulation to the amount of hydraulic binder I as previously defined.
  • the cementitious starting composition can contain a waterproofing or hydrophobicizing agent or additive.
  • these agents include a wide variety of organic or organo-siliceous compounds.
  • Ligaphob N(T) 90 by Peter Greven or Seal 200 by Elotex, in solid form, is employed as waterproofing additive.
  • the casting used to manufacture the product object of the present invention can contain various other additives so as to fine tune the characteristics of the mixture to the specific request.
  • these additives can be setting regulators, rheology modifiers or modifiers of physical-mechanical properties, such as for example celluloses or latexes, expansive, air entraining agents, air-releasing agents and tackifiers. These additives are optional for the purposes of the invention.
  • the cementitious composition of the present invention can also include the addition of fibres of various nature, such as inorganic fibres like metal fibres or glass and wollastonite fibres, and organic fibres, such as polyvinyl alcohol- or polypropylene-based fibres or aramid fibres, selected on the basis of the final application.
  • fibres of various nature such as inorganic fibres like metal fibres or glass and wollastonite fibres, and organic fibres, such as polyvinyl alcohol- or polypropylene-based fibres or aramid fibres, selected on the basis of the final application.
  • These fibres even in the form of sheets or mesh networks, can be added to reduce the fragility of the cementitious product both during the casting step and when subsequently glued onto a surface of the product and are chosen according to the final characteristics of the product and its use.
  • a mould preferably having horizontal walls, of a shape such as to give the final product the desired final geometry, a plate shape for example, is thus prepared.
  • the insert or inserts are arranged on the walls of the mould, preferably on the lower horizontal wall, by means of a secure but removable fixing system as previously described.
  • a planetary type mixer is fed: - a solid cementitious-based mixture comprising one or more components selected from cement, sand, aggregates, charges of mineral or pozzolanic origin, waterproofing and superfluidifying additives, if in solid form, rheology modifiers, fibres, pigments,
  • the solid-phase components are mixed in the planetary mixer for a period of time preferably between 30 seconds and 5 minutes, depending on the characteristics of the mixer and the external temperature, until a homogeneous mixture is obtained.
  • the liquid components, including the water, are then added and the mixing is continued for a time between 30 seconds and 10 minutes, again depending on the characteristics of the mixer and the external temperature.
  • the fresh mortar thus obtained is poured into the mould.
  • the high fluidity allows the homogeneous filling the mould even in the absence of vibration.
  • metal moulds of the type used for cementitious applications constituted by two matching halves, the internal surface of which can be coated with materials such as polyethylene terephthalate like Mylar® and the like, polycarbonate, polyamide, polymethylmethacrylate and the like, when there is a wish to impart high finish characteristic to the surface of the cementitious product from which the decorative insert emerges.
  • FIGS. 1 and 2 of the accompanying drawings show a perspective view of the non-limiting examples of a cementitious product according to the invention.
  • a cementitious, panel-shaped product 10 incorporates decorative inserts made of polymethylmethacrylate, thus with a coloured, transparency effect. These inserts are visible on the upper face 9 of the product 10.
  • Fig. 1 there is a single insert 11 in fluorescent polymethylmethacrylate having a spiral or winding shape, while in the case of figure 2 there are three inserts 12, 13, 14 having a segment shape with trapezoidal cross section, arranged in parallel, each in a different colour of polymethylmethacrylate.
  • Example 1 in particular describes the preparation of the product shown in Fig. 1.
  • a decorative insert having a spiral or winding shape was prepared by automatic computer aided cutting via laser, produced in fluorescent polymethylmethacrylate.
  • the insert with 3 mm thickness, was positioned and fixed with silicone grease onto the lower surface of a metal mould with horizontal walls coated with polycarbonate.
  • liquid components including the water, were then added and mixing continued for a time equal to three minutes depending on the characteristics of the mixer and the external temperature.
  • the fresh mortar obtained was poured into the mould having internal surface with micrometric surface roughness.
  • the fluidity allows homogeneous filling of the metal mould coated with polycarbonate without the application of vibrations to compact the cast mass.
  • the hardened product can be removed from the mould to subject it to the seasoning step, which takes place by storing it in a vertical position in a conditioned chamber at 20°C and 55% relative humidity.
  • a finished panel for ventilated facade having 60x60 cm dimensions and 15 mm thickness is thus obtained, with a decorative insert having a spiral or winding shape, that is visible on one face of the panel as shown in Fig. 1.
  • the thickness of the plate having a surface area equal to 40 x 40 cm 2 , was equal to 10 mm.
  • a decorative stainless steel insert was obtained by automatic computer aided cutting via laser.
  • the insert having a thickness of 2 mm, was positioned on the lower surface of the mould and fixed thereto using a vinyl-based adhesive.
  • the thickness of the 60x60 cm panel was equal to 4 cm.
  • a decorative marble insert was obtained by computer aided water-jet cutting.
  • the insert having a thickness of 2 cm, was positioned on the lower surface of the mould and fixed thereto using an adhesive.
  • the thickness of this sheet is 10 mm, with dimensions of 60x60 cm.
  • a decorative insert in fluorescent polymethylmethacrylate having a thickness of 3 mm was positioned and fixed onto the bottom of the mould, followed by casting of the fluid composition. Having extracted the plate from the mould, in order to accentuate the luminous properties of the insert with advertising function, it was placed in contact with a light source.
  • a cardboard decoration having a thickness of 2 mm, suitably fixed to the bottom, was used as insert.
  • the cardboard untreated for the purposes of the present invention, is therefore a hydrophilic material. It was consequently observed, during casting of the mortar, that the insert had begun to be impregnated with water. On release from the mould the insert presented as deformed as a result of water absorption, and with undefined contours as these were deformed due to inability to withstand the hydrostatic pressure of the cast fluid composition. The mortar thus being drawn between insert and mould, the aesthetic quality and coupling to cementitious material are unacceptable.
  • the quality of the finish of the concrete elements obtained after release from the mould according to the present invention is such that it does not require after-treatments such as sanding or polishing.
  • a product according to the present invention is generally suitable for a nonstructural use, principally as an architectural ornamental coating element and for design applications.
  • the prefabricated concrete products object of the present invention are intended for use in the construction industry for non-structural applications such as coating and covering elements of both the horizontal and vertical type, such as flat plates, ventilated facades, signs, infill panels and decorative elements or coatings for internal walls.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Finishing Walls (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

La présente invention porte sur un produit cimentaire à usage ornemental non structurel, en particulier pour des applications à des fins esthétiques et décoratives dans une architecture intégrée. Celui-ci est produit par coulée en moule d'une composition fluide comprenant : I. un liant hydraulique; II. un ou plusieurs agrégats; III. un agent anti-rétraction; IV. un agent super-fluidifiant; V. de l'eau, au moins un insert dans un matériau hydrophobe fixé au préalable à l'intérieur du moule restant incorporé sous la forme d'une marqueterie visible dans le produit après extraction du moule.
PCT/IB2013/059610 2012-10-25 2013-10-24 Produit cimentaire à usage ornemental non structurel Ceased WO2014064635A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP13820895.4A EP2911847A1 (fr) 2012-10-25 2013-10-24 Produit cimentaire à usage ornemental non structurel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT001818A ITMI20121818A1 (it) 2012-10-25 2012-10-25 Manufatto cementizio per uso ornamentale non strutturale, e metodo per la sua produzione
ITMI2012A001818 2012-10-25

Publications (1)

Publication Number Publication Date
WO2014064635A1 true WO2014064635A1 (fr) 2014-05-01

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Family Applications (1)

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PCT/IB2013/059610 Ceased WO2014064635A1 (fr) 2012-10-25 2013-10-24 Produit cimentaire à usage ornemental non structurel

Country Status (3)

Country Link
EP (1) EP2911847A1 (fr)
IT (1) ITMI20121818A1 (fr)
WO (1) WO2014064635A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB904037A (en) * 1960-02-16 1962-08-22 Antony Lynn Hollaway Forming cement or concrete articles having decorative surface designs
AT374728B (de) * 1981-12-16 1984-05-25 Fuerlinger Friedrich Verfahren zur herstellung einer ornamentstruktur an der oberflaeche von platten, schalen oder dgl.
EP0181739A1 (fr) 1984-10-30 1986-05-21 Blue Circle Industries Plc Compositions de ciment durcissables
EP0733603A1 (fr) * 1995-03-24 1996-09-25 Carla Milesi Mélange pour la formation de sols coulés sur place, de panneaux de revêtement ou similaires
EP1306356A1 (fr) 2001-10-24 2003-05-02 Ciments Francais Clinker sulfoalumineux sans fer et sans chaux libre, son procédé de préparation et son utilisation dans des liants blancs
WO2006018569A2 (fr) 2004-07-20 2006-02-23 Lafarge Clinker sulfoalumineux a haute teneur en belite, procede de fabrication d'un tel clinker et son utilisation pour la preparation de liants hydrauliques

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB904037A (en) * 1960-02-16 1962-08-22 Antony Lynn Hollaway Forming cement or concrete articles having decorative surface designs
AT374728B (de) * 1981-12-16 1984-05-25 Fuerlinger Friedrich Verfahren zur herstellung einer ornamentstruktur an der oberflaeche von platten, schalen oder dgl.
EP0181739A1 (fr) 1984-10-30 1986-05-21 Blue Circle Industries Plc Compositions de ciment durcissables
EP0733603A1 (fr) * 1995-03-24 1996-09-25 Carla Milesi Mélange pour la formation de sols coulés sur place, de panneaux de revêtement ou similaires
EP1306356A1 (fr) 2001-10-24 2003-05-02 Ciments Francais Clinker sulfoalumineux sans fer et sans chaux libre, son procédé de préparation et son utilisation dans des liants blancs
WO2006018569A2 (fr) 2004-07-20 2006-02-23 Lafarge Clinker sulfoalumineux a haute teneur en belite, procede de fabrication d'un tel clinker et son utilisation pour la preparation de liants hydrauliques

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
ADVANCES IN CEMENT RESEARCH, vol. 11, no. 1, January 1999 (1999-01-01), pages 15 - 21
J. H. SHARP ET AL.: "Calcium sulfoaluminates cements-low energy cements, special cements", ADVANCES IN CEMENT RESEARCH, vol. 11, no. 1, 1999, pages 3 - 13
JOHN W. PHAIR: "Green Chemistry for sustainable cement production and use", GREEN CHEM., vol. 8, 2006, pages 763 - 780

Also Published As

Publication number Publication date
EP2911847A1 (fr) 2015-09-02
ITMI20121818A1 (it) 2014-04-26

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