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WO2016000026A1 - Procédé de fabrication d'un élément de structure - Google Patents

Procédé de fabrication d'un élément de structure Download PDF

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Publication number
WO2016000026A1
WO2016000026A1 PCT/AU2015/000385 AU2015000385W WO2016000026A1 WO 2016000026 A1 WO2016000026 A1 WO 2016000026A1 AU 2015000385 W AU2015000385 W AU 2015000385W WO 2016000026 A1 WO2016000026 A1 WO 2016000026A1
Authority
WO
WIPO (PCT)
Prior art keywords
cement
mould
structural
structural member
blowing agent
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/AU2015/000385
Other languages
English (en)
Inventor
William Thompson
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.)
CSR Building Products Ltd
Original Assignee
CSR Building Products 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
Priority claimed from AU2014902557A external-priority patent/AU2014902557A0/en
Application filed by CSR Building Products Ltd filed Critical CSR Building Products Ltd
Publication of WO2016000026A1 publication Critical patent/WO2016000026A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • 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
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0015—Machines or methods for applying the material to surfaces to form a permanent layer thereon on multilayered articles
    • 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
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • 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
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/105—Metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/12—Mixture of at least two particles made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof

Definitions

  • the structural element may take the form of, and the method may be used to produce, a panel or sheet for use in construction and building applications, but it should be understood that the structural element and method are not so limited.
  • Geopolymers are generally formed from aluminosilicates.
  • Sources of aluminosilicate include naturally occurring clays such as kaolin, alushite, carnat, china clay, lithomarge, neokaolin, parakaolinite, pholenite, endellite, glossecolite, halloysite, milanite, berthiernine, fraignotite, grovenite, amesite, and chamoisite.
  • Industrial byproduct sources include flyash (being a by-product of e.g. coal combustion), slag from iron and steel production, and red mud (a by-product of the bauxite/alumina industry).
  • Such geopolymers are activated (i.e. to provide geopolymer binders and cements) by reacting the aluminosilicate source with an alkali in aqueous solution.
  • the resultant paste may be combined with aggregate material to provide a geopolymer cement that can represent an environmentally friendly alternative to the use of Portland cement.
  • Carefully formulated geopolymer concretes and cements can also offer high compressive strength at lower weights/densities than Portland cement.
  • US 4,509,985 discloses a mineral polymer composition employed for the making of cast or molded products at room temperatures, or temperatures generally up to 120° C.
  • the method for preparing the mixture comprises dissolving in water an aluminosilicate oxide, alkali (e.g. a strong alkali such as sodium hydroxide and/or potassium hydroxide), and a colloidal silica sol or alkali polysilicate.
  • alkali e.g. a strong alkali such as sodium hydroxide and/or potassium hydroxide
  • colloidal silica sol or alkali polysilicate e.g. a colloidal silica sol or alkali polysilicate.
  • US 5,356,579, US 5,788,762, US 5,626,665, US 5,635,292, US 5,637,412 and US 5,788,762 disclose geopolymer cement systems with enhanced compressive strengths or low density for construction applications.
  • WO20071 19121 teaches the addition to geopolymer mixtures of blowing agents such as metal powders, hydrocarbons, organic materials, carbonates, bicarbonates, nitrates, nitrites, sulfates, sulphites, sulfides, water, and other compounds that can generate gas upon exposure to high pH, heat, or a chemical reaction.
  • blowing agents such as metal powders, hydrocarbons, organic materials, carbonates, bicarbonates, nitrates, nitrites, sulfates, sulphites, sulfides, water, and other compounds that can generate gas upon exposure to high pH, heat, or a chemical reaction.
  • Finely ground aluminium metal powder is taught as a specific example of a blowing agent that produces hydrogen upon exposure to a high pH solution.
  • blowing agents disclosed include a gas pocket that expands upon heating and chemically-bound water that converts to steam upon heating.
  • WO 2013044324 discloses a method for manufacturing a cellular geopolymer (e.g. fly ash-based) product that forms a self-supporting structure (e.g. a sheet or panel that is formed in a mould).
  • the intention of the method is to produce a cellular structure that is uniform within the bulk of the product with respect to size and distribution of open cells (voids), but that exhibits more densified regions at surfaces in contact with the walls of the mould formwork due to bubble collapsing.
  • the cellular structure that is produced is retained upon curing to provide the self-supporting structure.
  • WO 2013044324 may comprise a dense skin that produces a surface suitable for decorating, the dense skin does not contribute sufficiently to structural strength (e.g. it has little tensile strength).
  • dense skin does not contribute sufficiently to structural strength (e.g. it has little tensile strength).
  • densification can only be achieved on one surface, not both (e.g. not at an underlying surface of a sheet or panel when formed horizontally in a mould).
  • the product requires steel reinforcement to provide sufficient strength for its removal from the mould and for its subsequent handling.
  • 2013044324 e.g. densification at the surface, foaming for light weight, bonding to the structural steel, corrosion protection of the steel, etc
  • 2013044324 in practice requires careful selection and processing of the waste fly ash. This at present limits the selection of suitable waste products, and further imposes transport costs and minimises the opportunity to source raw material at a low cost.
  • the above references to the background art do not constitute an admission that the art forms part of the common general knowledge of a person of ordinary skill in the art.
  • the above references are also not intended to limit the application of the method and structural element as disclosed herein.
  • the structural element can, for example, provide a composite product having structural (e.g. support (load-bearing), self-standing, handling, transportable, etc) properties.
  • the composite product can be formed without requiring e.g. reinforcing (e.g. steel) bars or rods therewithin.
  • the method may overcome at least some of the shortcomings with the product produced according to the method of WO 2013044324.
  • the method comprises adding a mineral binder to an aqueous solution to form a cement.
  • the mineral binder may, for example, comprise a geopolymer and/or Portland cement.
  • Other mineral binders e.g. plaster, non-hydraulic cements such as lime-based cements, pozzolans, etc
  • organic polymer binders may be added thereto.
  • the method also comprises delivering (e.g. pouring, casting, pumping, flowing, etc) the cement into a mould.
  • the method further comprises arranging at least one structural member with respect to the cement in the mould such that the cement is able to bind to the at least one structural member. This can form a composite product having the aforementioned structural properties.
  • the cement can be allowed to cure in contact with the at least one structural member in the mould until the resultant structural element has sufficient strength for its removal from the mould and e.g. for its subsequent handling. Further curing may take place thereafter (e.g. during storage, transportation or even in situ (i.e. when in use)).
  • the at least one structural member comprises a panel or sheet that is arranged in the mould such that the cement is able to bind to a major face of the at least one structural member.
  • the panel or sheet may comprise a structural building material (i.e. a building material having structural properties, typically structural properties that are in excess of the geopolymer).
  • the at least one structural member may be of fibre cement.
  • the use of fibre cement can, for example, avoid the use of reinforcing (e.g. steel) bars or rods within the cement.
  • the fibre of the fibre cement may comprise organic fibre such as cellulose fibre; glass fibre; and/or polymer fibre.
  • the structural element may comprise first and second structural members arranged in the mould to sandwich the cement that is formed from the mineral binder. However, more than two such structural members may be arranged around the cement in e.g. a block-like structure, column, etc.
  • the first structural member may first be arranged in the mould (e.g. in, at, or as a base of the mould).
  • the cement (optionally comprising a blowing agent) can be delivered at the first structural member in the mould (e.g. poured or cast onto, flowed or spread over, etc the first structural member).
  • the second structural member may be arranged at the cement to sandwich the cement between it and the first structural member.
  • the cement is able to bind to both the first and second structural members to form a composite structural element.
  • first and second structural members can be constrained in the mould during curing of the cement.
  • the cement in the mould expands against the first and second structural members (e.g. due to an action of a blowing agent, or otherwise)
  • its further expansion is able to be restrained by those members (and thence by the mould).
  • the cement may further comprise a blowing agent that causes the cement to expand in the mould (e.g. due to foaming, aeration, pore formation, bubbling, etc).
  • the blowing agent may be mixed with the cement prior to delivering it into the mould.
  • the blowing agent can alternatively be added thereafter and prior to delivering the cement into the mould. It may even be mixed into the cement once in the mould, though this is less desirable/more
  • the blowing agent may comprise one or more of: a metal powder; a
  • hydrocarbon-based blowing agent an organic-based blowing agent (e.g. organic foam); a carbonate- or bicarbonate-based blowing agent; a nitrate- or nitrite -based blowing agent; a sulfate-, sulphite-, or sulphide-based blowing agent; water; or another compound that can generate a gas upon exposure to high pH, heat and/or a chemical reaction.
  • the blowing agent is a metal powder, it may e.g. comprise finely ground aluminium metal powder that produces hydrogen upon contact with an alkali of the cement (e.g. 4A1 + OH " + H 2 0 ⁇ 2A1 2 0 " + 3 / 2 H 2 ).
  • the hydrogen gas can function to foam and expand the cement in the mould with some considerable pressure (e.g. 10-50 KPa - see WO2007119121)).
  • the at least one structural member e.g. each of the first and second structural members
  • the at least one structural member can be constrained with respect to the mould.
  • the expanding cement when cement together with a blowing agent is delivered to the mould, the expanding cement can expand against and bind to the structural member(s) to form the structural element.
  • the constrained structural member(s) can thus contain the expanding cement, causing it to collapse in on itself (i.e. gas voids and pockets within the cement collapse). This can provide densified regions adjacent to the structural member(s).
  • the geopolymer can comprise an
  • aluminosilicate may be combined with Portland cement.
  • the aluminosilicate can be mixed together with an alkali in aqueous solution to cause a geopolymer cement to form (e.g. as a paste, slurry, premix, gel, etc). This geopolymer cement can then be delivered into the mould.
  • the aluminosilicate may comprise one or more of: naturally occurring clay such as kaolin (or other of the clays as set forth above).
  • the aluminosilicate may further comprise an industrial by-product such as flyash, and/or slag from iron and steel production, and/or red mud from the production of alumina.
  • the aluminosilicate may comprise a mixture of flyash and blast furnace slag from iron and steel production.
  • the alkali for the geopolymer may comprise one or more of alkali metal and alkaline earth metal salts of hydroxide, halide and silicate.
  • the alkali may comprise an alkali silicate.
  • the silicate can also assist the structural properties of the resultant geopolymer cement.
  • the cement may be combined with aggregate material (e.g. sand, stone, etc) to provide a concrete or mortar that is delivered into the mould.
  • aggregate material e.g. sand, stone, etc
  • the aggregate material may further comprise lightweight aggregate (e.g.
  • volcanic pumice Perlite microspheres, cenospheres; thermally treated natural raw materials such as clay, slate or shale; etc).
  • one or more of viscosity, temperature, extent of blowing agent and curing time of the cement can be controlled to enhance the forming of the structural element.
  • formwork for the mould can be provided that is able to accommodate (e.g. withstand) the pressure that is caused within and by the cement (e.g. as a result of gas generated by the blowing agent causing the cement to expand).
  • a structural element that comprises at least one structural member.
  • the structural element also comprises a mineral binder cement bound to a major face of the at least one structural member.
  • the structural element may comprise first and second structural members.
  • the mineral binder cement may define a core that is arranged between and bound to opposing major faces of the first and second structural members.
  • the mineral binder cement may comprise a geopolymer and/or Portland cement.
  • the at least one structural member may be of fibre cement (e.g. a sheet or panel), which fibre may comprise an organic (e.g. cellulose), glass and/or polymer fibre.
  • the structural element may otherwise be as defined in or formed according to the method as set forth above.
  • the structural element can define a composite product that has the structural properties (e.g. support, self-standing, handling, transportable, etc) as set forth above.
  • the core may take the form of a rectangular prism (panel), and the first and second structural members may be arranged at and bound to opposing major faces of the rectangular prism to define a composite panel of structural building material. Further, the first and second structural members may be arranged to sandwich the geopolymer core therein.
  • Figure 1 shows a schematic side view of an embodiment of a product resulting from the method as set forth in the Summary.
  • FIG. 1 a method for forming a structural element in the form of a composite panel 10 is schematically depicted.
  • the composite panel 10 can be formed according to a method as set forth in the Example below.
  • FIG 1A schematically depicts the components of the composite panel 10, namely, a cement core 12 and opposing fibre cement sheets or panels 14, 16.
  • the cement of the core 12 can comprise a mineral binder which, when mixed with an aqueous solution, forms the cement.
  • the mineral binder may, for example, comprise a geopolymer and/or Portland cement (e.g. a mixture thereof).
  • Other mineral binders e.g. plaster, non-hydraulic cements such as lime-based cements, pozzolans, etc
  • organic polymer binders may also be added to the cement to enhance its properties.
  • Figure IB schematically depicts a mould 20 in which the composite panel 10 is able to be formed by casting. Accessories for the mould to retain/restrain the components of the composite panel 10 during curing are omitted for clarity.
  • the composite panel 10 resulting from the method is shown in Figure 1C.
  • the composite panel 10 has, for example, structural properties including a supporting (load- bearing) capacity, an ability to self-stand, handling and transportation capabilities, ease of removal from the mould, etc.
  • the composite panel 10 and its method of formation can overcome at least some of the shortcomings with the product produced according to the method of WO
  • the opposing fibre cement sheets 14, 16 that are bound to the core 12 can provide the requisite degree of reinforcing for the structural purposes as set forth above.
  • the fibre cement sheets or panels 14, 16 are able to absorb compressive and tensile loads in bending to provide sufficient stiffness and strength to the composite panel 10, further avoiding the need for steel reinforcement.
  • the fibre cement sheets or panels 14, 16 can employ one or more organic (e.g. cellulose), glass or polymer reinforcing fibres (e.g. Cemintel® fibre cement panels as produced by CSR Building Products can be employed).
  • the surface of the fibre cement sheets or panels 14, 16 are also able to receive a variety of decorative finishes, in contrast to a raw cement external face.
  • the cement core 12 can be more simply formulated to provide just the function of a core element (e.g. to accept shear stresses during bending and to provide impact resistance). This can enable a wide variety of, for example, industrial byproducts (e.g. waste fly ash, Bayer red mud residue, etc), and products of varying grades, to be used in forming the cement core. This represents a further simplification over the method of WO 2013044324.
  • cement core 12 Whilst the cement core 12 is shown with two sheets or panels 14, 16 bound to opposing major faces thereof, having just one sheet or panel bound to a major face of the cement core 12 can still provide a number of the structural properties and benefits as set forth above.
  • the cement core 12 takes the form of a rectangular prism (i.e. a panel in its own right).
  • the sheets/panels 14, 16 are arranged at and bound to opposing major faces of the rectangular prism to define the composite panel 10. More
  • the sheets/panels 14, 16 are arranged to sandwich the cement core 12 therein.
  • a method for forming the composite panel 10 in mould 20 first comprised mixing in a separate mixing pot (not shown) an aluminosilicate together with an alkali in aqueous solution to form a geopolymer mix (e.g. a paste, slurry, premix, gel, etc).
  • the geopolymer mix was optionally able to comprise a proportion of Portland cement and/or other mineral binders such as plaster, non-hydraulic cements such as lime-based cements, pozzolans, etc, as well as organic polymer binders (e.g. EVA, PV Alcohol, etc).
  • a preferred aluminosilicate was flyash due to its abundance (being a by-product of coal combustion). Flyash at around 10-15 wt. % was added.
  • Other optional aluminosilicates to be added included naturally occurring clays (such as kaolin or other of the clays as set forth above); slag from iron and steel production (such as blast furnace slag); red mud from the production of alumina, etc.
  • the alkali initiator When using an aluminosilicate binder, the alkali initiator was able to comprise a mixture of alkali metal and alkaline earth metal salts of hydroxide, halide and silicate.
  • a preferred alkali was an alkali metal (e.g. sodium and/or potassium) silicate in water (30- 40% solids) at around 15-20 wt. %, whereupon the silicate also assisted the structural properties of the resultant cement core.
  • a calcium-containing component was added to help promote geo- polymerisation (e.g. blast furnace slag and/or Portland cement).
  • the cement comprised a mixture of fiyash and blast furnace slag and/or Portland cement, the latter two components at around 5-10 wt. %.
  • the cement core 12 to be formed could either take the form of a concrete or mortar.
  • an aggregate such as sand at around 50-85 wt. % was added.
  • Lightweight aggregate such as volcanic pumice, Perlite microspheres, cenospheres, or thermally treated (e.g. calcined) shales or clays were also able to be added in place of some of the sand. Stone such as blue metal, etc. was able to be added to form a cement.
  • blowing agent was optimally added to cause expansion and forming of the resultant mixture, the blowing agent usually being dosed into the cement mixing pot for ease of formulation.
  • a preferred blowing agent was a metal powder such as finely ground aluminium metal powder at 1 wt. % or less, with the aluminium metal powder producing hydrogen gas upon contact with alkali materials in the cement mix according to the equation:
  • blowing agent because the sheets/panels 14, 16 provided the structural properties to the composite product, the use of a blowing agent was not essential.
  • other blowing agents that were able to be used included hydrocarbon-based blowing agents; organic-based blowing agents such as organic foam; carbonate- and bicarbonate-based blowing agents; nitrate- and nitrite-based blowing agents; sulfate-, sulphite-, and sulphide-based blowing agents; and even water that was heated in the mould to generate steam, or other compounds that generated a gas upon exposure to high pH, heat and/or the geopolymer chemical reaction.
  • the resultant cement pot mix also was delivered by pouring (or by being pumped) into the mould 20.
  • the mould 20 had been pre-prepared by cleaning it from residue and by arranging one of the fibre cement panels 16 in the mould at a base 22 thereof.
  • the cement pot mix was poured into the mould and spread evenly (e.g.
  • the other fibre cement panel 14 was then arranged over the evenly spread mix, and this panel was then restrained thereat. This restraint was achieved either by providing bracing fixtures located at the braced 23, side walls 24 of the mould and/or at end walls 26 of the mould. The bracing fixtures held the sheet 14 in place. Alternatively, a locking/sealing lid (not shown) was positioned over the opening 28 of the mould. The blowing agent (when added) caused the cement to expand (e.g. due to foaming and bubbling by the hydrogen gas), thereby causing the lower sheet 16 to be driven into the mould base, and the upper sheet 14 to be driving against the bracing or lid.
  • fibre cement sheets 14, 16 also meant that, instead of using a blowing agent, pressure could instead be applied to a lid or cover plate to aid in binding of the core 12 to the sheets 14, 16.

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention concerne un procédé de formation d'un élément de structure (10) comprenant l'ajout d'un liant minéral à une solution aqueuse pour former un ciment. Le procédé comprend également la distribution du ciment dans un moule (20). Le procédé comprend en outre l'étape consistant à agencer au moins un élément de structure (14, 16) par rapport au ciment dans le moule de telle sorte que le ciment soit capable de se lier à l'au moins un élément de structure, et puisse également former un noyau (12). Un élément de structure (10) comprend l'au moins un élément de structure (14, 16), et un ciment à liant minéral (12) lié à une face principale de l'au moins un élément de structure.
PCT/AU2015/000385 2014-07-03 2015-07-01 Procédé de fabrication d'un élément de structure Ceased WO2016000026A1 (fr)

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CN107867875A (zh) * 2016-09-28 2018-04-03 日吉华株式会社 建材和建材的制造方法
JP2018052767A (ja) * 2016-09-28 2018-04-05 ニチハ株式会社 建材の製造方法、及び建材
JP2018052769A (ja) * 2016-09-28 2018-04-05 ニチハ株式会社 建材とその製造方法
CN108455887A (zh) * 2018-03-13 2018-08-28 山东大学 利用闷渣法协同赤泥制备固废基地质聚合物的方法
CN110395923A (zh) * 2019-07-25 2019-11-01 桂林理工大学 一种多元固废地聚物基免烧砖的制备方法
CN111660421A (zh) * 2020-06-15 2020-09-15 江苏道通新材料科技有限公司 一种河道淤泥与水泥基材复合多层板成型的生产线及成型方法
EP4375058A1 (fr) * 2022-07-13 2024-05-29 Koller Kunststofftechnik GmbH Corps moulés plats en forme de sandwich

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Publication number Priority date Publication date Assignee Title
CN107867875A (zh) * 2016-09-28 2018-04-03 日吉华株式会社 建材和建材的制造方法
JP2018052767A (ja) * 2016-09-28 2018-04-05 ニチハ株式会社 建材の製造方法、及び建材
JP2018052769A (ja) * 2016-09-28 2018-04-05 ニチハ株式会社 建材とその製造方法
EP3308917A1 (fr) * 2016-09-28 2018-04-18 Nichiha Corporation Matériau de construction et son procédé de production
RU2743743C2 (ru) * 2016-09-28 2021-02-25 Нитиха Корпорейшн Строительный материал и способ получения строительного материала
CN107867875B (zh) * 2016-09-28 2023-02-17 日吉华株式会社 建材和建材的制造方法
CN108455887A (zh) * 2018-03-13 2018-08-28 山东大学 利用闷渣法协同赤泥制备固废基地质聚合物的方法
CN110395923A (zh) * 2019-07-25 2019-11-01 桂林理工大学 一种多元固废地聚物基免烧砖的制备方法
CN111660421A (zh) * 2020-06-15 2020-09-15 江苏道通新材料科技有限公司 一种河道淤泥与水泥基材复合多层板成型的生产线及成型方法
CN111660421B (zh) * 2020-06-15 2021-11-12 江苏道通新材料科技有限公司 一种水泥基复合河道淤泥多层板成型的生产线及成型方法
EP4375058A1 (fr) * 2022-07-13 2024-05-29 Koller Kunststofftechnik GmbH Corps moulés plats en forme de sandwich

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