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WO2015136290A1 - Matériau de construction et son procédé de fabrication - Google Patents

Matériau de construction et son procédé de fabrication Download PDF

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Publication number
WO2015136290A1
WO2015136290A1 PCT/GB2015/050722 GB2015050722W WO2015136290A1 WO 2015136290 A1 WO2015136290 A1 WO 2015136290A1 GB 2015050722 W GB2015050722 W GB 2015050722W WO 2015136290 A1 WO2015136290 A1 WO 2015136290A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibres
rubber
chemical admixture
construction material
rubber pieces
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/GB2015/050722
Other languages
English (en)
Inventor
Richard Elliott
Dominic DILLON
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.)
ENVIROMATE Ltd
Original Assignee
ENVIROMATE 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 ENVIROMATE Ltd filed Critical ENVIROMATE Ltd
Publication of WO2015136290A1 publication Critical patent/WO2015136290A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/20—Waste materials; Refuse organic from macromolecular compounds
    • C04B18/22—Rubber, e.g. ground waste tires
    • 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
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1003—Non-compositional aspects of the coating or impregnation
    • 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
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1018—Coating or impregnating with organic materials
    • 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
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1018—Coating or impregnating with organic materials
    • C04B20/1029—Macromolecular compounds
    • C04B20/1033—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • 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
    • 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

  • This invention relates to a construction material and to a method of manufacturing a construction material.
  • this invention relates to a construction material comprising cement, rubber, fibres and chemical admixtures, and to a method of manufacturing such a material.
  • Concrete comprising cement, water and aggregate, has a large number of different uses as a construction material. These uses include the construction of load bearing surfaces such as roads and runways, structures such as buildings and bridges, and underground foundations and supports. Concrete may be pre-cast to form blocks and other structures, or may be cast in- situ, for example when forming foundations or a road surface. Furthermore, the concrete may be manufactured in a plant and then transported to site, or may be mixed on site. Whichever way the concrete is manufactured, the time within which the concrete can be worked, i.e. the time between mixing of the ingredients and the hardening of the concrete, is limited. This is referred to as the curing time of the concrete.
  • chemical admixtures may be used to alter the properties of the concrete during manufacture and curing of the concrete, and/or to modify the properties of the concrete once it has hardened. It is also known to vary the aggregate that is used in the concrete to achieve different physical properties of the final hardened concrete, to lower the cost of concrete manufacture, or to provide a more decorative finish. In particular, it is known to include rubber pieces in concrete in order to improve the toughness or flexibility of the final material. Such materials are known for use in surfaces such as walkways and playing surfaces.
  • a method of manufacturing a construction material comprising cement, rubber pieces and fibres, and the method comprising the steps of:
  • pre-treating the rubber pieces and/or fibres by applying a chemical admixture to said rubber and/or fibres and leaving the rubber and/or fibres to absorb at least some of the chemical admixture over a period of at least two hours;
  • the rubber pieces and/or fibres are preferably left for a period of at least eight hours, and more preferably for a period of at least twenty-four hours, before being mixed with the other ingredients of the construction material.
  • the rubber pieces and fibres are preferably obtained from chopped up or shredded car tyres.
  • the step of applying a chemical admixture to said rubber and/or fibres will typically comprise spraying said rubber pieces and/or fibres with a liquid chemical admixture. In some embodiments, however, it may be desirable to mix said rubber pieces and/or fibres with the liquid chemical admixture.
  • the construction material comprises rubber pieces having at least partially embedded fibres
  • the method preferably comprises spreading said rubber pieces over a support surface and spraying said rubber pieces with chemical admixture.
  • the support surface preferably comprises a conveyor belt arranged such that the spraying of the rubber pieces and fibres with the chemical admixture is a continuous process.
  • the amount of chemical admixture applied to the rubber pieces and/or fibres is between 2 litres per 1000 kg of rubber and/or fibres and 5 litres per 1000 kg of rubber and/or fibres. More preferably the amount of chemical admixture applied to the rubber pieces and/or fibres is between 3 litres per 1000 kg of rubber and/or fibres and 4 litres per 1000 kg of rubber and/or fibres.
  • the chemical admixture is selected from the following: an air-entraining chemical admixture; a water-reducing chemical admixture;
  • a construction material comprising cement, rubber pieces and fibres, in which the rubber pieces and/or fibres include an absorbed chemical admixture.
  • the rubber pieces and fibres are preferably in the form of chopped up or shredded car tyres. As such, the fibres may be at least partially embedded in the rubber pieces.
  • the chemical admixture is preferably selected from the following:
  • said material may further comprise a mineral filler selected from sand, glass, flyash and bottom ash.
  • the rubber pieces have a size range of 5 to 30 mm.
  • the rubber content is between 30% and 90% by volume of the dry ingredients of the construction material.
  • the rubber content is between 45% and 65% by volume of the dry ingredients of the construction material.
  • the construction material of the present invention is a cementitious material comprising cement, rubber pieces and fibres.
  • the rubber pieces and the fibres may be provided separately; however, it is preferable if the fibres are at least partially embedded in the rubber pieces.
  • fibre-reinforced rubber is obtained from chopped up or shredded vehicle tyres, such as car tyres. This rubber material, therefore, includes fabric fibres that were part of the reinforcement used in the tyres. Typically these fibres will be made from polyester or nylon.
  • the rubber pieces will typically have dimensions of less than 50 mm, and more preferably between 5 mm and 30 mm.
  • the rubber pieces act as aggregate in the construction material and, once water is added, the fibres act to bond the rubber pieces together within a matrix of cement.
  • the resultant material may, therefore, be described as a rubber concrete.
  • the use of rubber as an aggregate gives the resultant concrete material toughness and flexibility, unlike traditional concrete made with hard, mineral aggregates.
  • the construction material may also include additional aggregate, or one or more mineral fillers or admixtures.
  • additional aggregate or one or more mineral fillers or admixtures.
  • These may comprise, for example, sand, glass, flyash or bottom ash.
  • a variety of other aggregates and mineral admixtures are known to the person skilled in the art, and may be selected based on the desired properties and final uses of the construction material.
  • These additional aggregates and mineral fillers may be incorporated, for example, to increase the strength or density of the final material, or to produce a desired surface finish.
  • the rubber pieces and fibres together will typically form between 30% and 90% by volume of the dry components (cement, rubber, fibres, aggregates, mineral admixtures) of the construction material.
  • the dry components comprise between 50% and 60% by volume rubber pieces and fibres.
  • One particularly preferred embodiment of the construction material comprises 1 part (by volume) cement, 2 parts mineral filler, e.g. sand, and 3 parts shredded car tyres.
  • a second preferred embodiment comprises 1 part (by volume) cement, 2 parts mineral filler, e.g. sand, and 4 parts shredded car tyres.
  • water is added to the above described dry components to produce a wet mix of the required consistency, either to pre-cast blocks or slabs for example, or to cast the construction material in situ.
  • a number of different chemical admixtures may be included in the material.
  • chemical admixtures may be added to traditional concrete to modify the properties of the uncured, wet concrete mix and/or the properties of the cured, hardened concrete. These chemical admixtures are typically classified in five main classes, although other chemical admixtures will be known to persons of skill in the art.
  • Air-entraining admixtures comprise surfactants that improve the workability of the wet mix material by stabilising air within the material.
  • the use of air-entraining admixtures can also improve the resistance of the hardened concrete to frost damage (freeze-thaw damage).
  • Suitable air-entraining chemical admixtures may comprise salts of wood resins, salts of sulfonated hydrocarbons and salts of fatty and resinous acids.
  • Water-reducing admixtures comprise surfactants that disperse the cement particles within the mix.
  • the addition of these chemicals can be used to reduce the amount of water in the mix. If the amount of water is reduced, for a given cement content, then the compressive strength of the resultant material can be increased. Alternatively, if the amount of water is reduced, but it is not necessary or desired to increase the compressive strength of the final material, then the amount of cement can also be reduced, which has environmental benefits.
  • These water-reducing chemical admixtures can be used to decrease the water content by up to about 10%. Suitable water-reducing chemical admixtures may comprise lignosulfonates or hydroxylated carboxylic acid.
  • Retarding admixtures these slow down the rate of curing or hardening of the concrete, allowing the wet mix to be transported or worked for a longer time. This is particularly advantageous in hot weather, to counteract the accelerated curing times caused by the increased temperatures.
  • Suitable retarding chemical admixtures may comprise lignin or sugars.
  • Accelerating admixtures these increase the rate of curing or hardening of the concrete by increasing the rate of the chemical reaction between the cement and the water.
  • the use of these chemical admixtures may be advantageous in cold weather.
  • Suitable accelerating chemical admixtures may comprise calcium chloride or calcium nitrate.
  • Plasticizers or superplasticizers these have a similar action to the water reducing chemical admixtures described above. In order to achieve a plasticizing effect and, therefore, to improve the workability and flow of the wet mix, the water content is not reduced and the lubricating effects of the admixture are utilised. These chemical admixtures, therefore, increase the slump of the wet concrete mix.
  • Suitable plasticizers or superplasticizers may comprise lignosulfonates or polycarboxylates.
  • the rubber pieces and/or fibres are pre-treated with a chemical admixture before being mixed with the rest of the dry ingredients or the water.
  • Pre-treatment of the rubber pieces and/or fibres comprises applying a chosen chemical admixture to the rubber pieces and/or fibres such that the rubber pieces and/or fibres absorb at least some of the chemical admixture.
  • the rubber and/or fibres must, therefore, have some degree of absorbency so that they are able to soak up at least some of the chemical admixture that is applied to them.
  • both the fibres and the rubber will have some degree of absorbency.
  • the rubber pieces and fibres are provided separately, it may be desirable to only pre- treat one of these components, and this will typically be the component with the greatest absorbency.
  • the chemical admixture is in the form of a liquid admixture that is, preferably, applied to the rubber pieces and fibres by spraying. In some embodiments, however, the rubber pieces and/or fibres may be mixed with the liquid admixture.
  • the rubber pieces and/or fibres Once the rubber pieces and/or fibres have been coated with the chemical admixture either by spraying or mixing, they are then left to absorb the admixture over a period of at least two hours. Preferably the rubber pieces and/or fibres are left for a period of at least eight hours, and more preferably at least twenty-four hours, to fully absorb the chemical admixture.
  • the amount of chemical admixture applied to the rubber pieces and/or fibres may vary depending on a number of factors such as, the type of rubber, the type of fibres, and the way in which the shredded rubber is manufactured. Typically, however, the amount of chemical admixture applied to the rubber pieces and/or fibres will be between 2 litres and 5 litres per 1000 kg of rubber and/or fibres. More preferably the amount of chemical admixture applied to the rubber pieces and/or fibres is between 3 litres and 4 litres per 1000 kg of rubber and/or fibres.
  • vehicle tyres are shredded to form pieces of fibre-reinforced rubber, using a process known in the art.
  • the fibre-reinforced rubber pieces are carried on a conveyor belt.
  • the rubber pieces are sprayed with the required chemical admixture using appropriate spray heads. Because the rubber pieces are substantially evenly spread over the conveyor belt and the conveyor belt is passing the spray heads at a constant rate, the fibre-reinforced rubber pieces are evenly coated with the chemical admixture and a substantially uniform absorption by the rubber and fibres is achieved.
  • the fibre-reinforced rubber is then stored to allow the rubber and fibres to fully absorb the chemical admixture over a period of about 24 hours.
  • the pre-treated fibre-reinforced rubber is then mixed with cement in the desired ratio.
  • water is added to the dry ingredients either at a central facility or on site. Upon adding the water, the chemical admixture is slowly released from the rubber and fibres and is dispersed evenly throughout the wet mix.
  • the present invention therefore, provides an improved method of manufacture of a construction material comprising cement, rubber and fibres, and an improved construction material.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Civil Engineering (AREA)
  • Road Paving Structures (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

La présente invention concerne un matériau de construction et un procédé de fabrication d'un matériau de construction. La présente invention concerne en particulier un matériau de construction comprenant du ciment, du caoutchouc, des fibres et des mélanges d'agents chimiques, et un procédé de fabrication d'un tel matériau. Un procédé de fabrication d'un matériau de construction, ledit matériau de construction comprenant du ciment, des morceaux de caoutchouc et des fibres, comprend les étapes de prétraitement des morceaux de caoutchouc et/ou des fibres par application d'un mélange d'agents chimiques audit caoutchouc et/ou auxdites fibres, et le fait de laisser les caoutchoucs et/ou les fibres pour absorber au moins une partie du mélange chimique sur une période d'au moins deux heures ; puis le mélange dudit caoutchouc et/ou desdites fibres prétraitées avec du ciment et de l'eau pour former ledit matériau de construction.
PCT/GB2015/050722 2014-03-12 2015-03-12 Matériau de construction et son procédé de fabrication Ceased WO2015136290A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1404364.0A GB2524045A (en) 2014-03-12 2014-03-12 Construction material and method of manufacturing the same
GB1404364.0 2014-03-12

Publications (1)

Publication Number Publication Date
WO2015136290A1 true WO2015136290A1 (fr) 2015-09-17

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WO (1) WO2015136290A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11299886B2 (en) 2019-04-24 2022-04-12 Protectiflex, LLC Composite stud wall panel assembly

Citations (10)

* Cited by examiner, † Cited by third party
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DE2606511A1 (de) * 1976-02-18 1977-08-25 Rabit Bautenschutzmittel Gmbh Verfahren zur herstellung von beton mit zumischung von saugfaehigen zuschlagstoffen und zusaetzen und substanzen zur durchfuehrung des verfahrens
WO1995011862A1 (fr) * 1993-10-28 1995-05-04 Cretetech Development Limited Materiau de construction renfermant un ciment hydraulique et une matiere ligneuse enrobee a titre de matiere de charge
WO1998058887A1 (fr) * 1997-06-25 1998-12-30 W.R. Grace & Co.-Conn. Adjuvant et procede destine a optimiser l'ajout d'un superplastifiant d'eo/po a un beton renfermant des agregats d'argile smectique
JP2000335986A (ja) * 1999-05-31 2000-12-05 Daicel Chem Ind Ltd 被覆肥料粒を含む多孔質セメント硬化体
JP2001220188A (ja) * 2000-02-01 2001-08-14 Taiheiyo Cement Corp 軽量骨材用被覆材料および被覆軽量骨材
WO2003068702A2 (fr) * 2002-02-14 2003-08-21 Rhodianyl Matériaux composites obtenus à partir de liant hydraulique et de fibres organiques présentant un comportement mécanique amélioré
WO2006016499A1 (fr) * 2004-08-09 2006-02-16 Hagihara Industries Inc. Fibres de résine thermoplastique destinées à renforcer le ciment
GB2437280A (en) * 2006-04-21 2007-10-24 Peter Hammond Concrete incorporating organic liquids or solids treated with super critical carbon dioxide
CN101343166A (zh) * 2008-07-18 2009-01-14 北京工业大学 一种抗冲击的生态混凝土的制备方法
WO2014015289A1 (fr) * 2012-07-20 2014-01-23 U.S. Concrete, Inc. Compositions de béton à séchage accéléré et procédés de fabrication de celles-ci

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WO1995011862A1 (fr) * 1993-10-28 1995-05-04 Cretetech Development Limited Materiau de construction renfermant un ciment hydraulique et une matiere ligneuse enrobee a titre de matiere de charge
WO1998058887A1 (fr) * 1997-06-25 1998-12-30 W.R. Grace & Co.-Conn. Adjuvant et procede destine a optimiser l'ajout d'un superplastifiant d'eo/po a un beton renfermant des agregats d'argile smectique
JP2000335986A (ja) * 1999-05-31 2000-12-05 Daicel Chem Ind Ltd 被覆肥料粒を含む多孔質セメント硬化体
JP2001220188A (ja) * 2000-02-01 2001-08-14 Taiheiyo Cement Corp 軽量骨材用被覆材料および被覆軽量骨材
WO2003068702A2 (fr) * 2002-02-14 2003-08-21 Rhodianyl Matériaux composites obtenus à partir de liant hydraulique et de fibres organiques présentant un comportement mécanique amélioré
WO2006016499A1 (fr) * 2004-08-09 2006-02-16 Hagihara Industries Inc. Fibres de résine thermoplastique destinées à renforcer le ciment
GB2437280A (en) * 2006-04-21 2007-10-24 Peter Hammond Concrete incorporating organic liquids or solids treated with super critical carbon dioxide
CN101343166A (zh) * 2008-07-18 2009-01-14 北京工业大学 一种抗冲击的生态混凝土的制备方法
WO2014015289A1 (fr) * 2012-07-20 2014-01-23 U.S. Concrete, Inc. Compositions de béton à séchage accéléré et procédés de fabrication de celles-ci

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Also Published As

Publication number Publication date
GB2524045A (en) 2015-09-16
GB201404364D0 (en) 2014-04-23

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