Lightweight building material and method of producing the same

• US 4,462,835 A
• Filed: 07/28/1982
• Issued: 07/31/1984
• Est. Priority Date: 08/08/1981
• Status: Expired due to Fees

• Current Assignee: Otavi Minen AG (Parjointco N.V.)
• Original Assignee: Otavi Minen AG (Parjointco N.V.)
• Inventors: Car, Martin
• Primary Examiner(s): Poer, James
• Application Number:
  US06/402,820
• Time in Patent Office: 734 Days
• Field of Search: 106/75, 106/DIG. 2
• US Class Current: 106/602
• CPC Class Codes: C04B 14/02 Granular materials , e.g. microballoons
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 28/24 containing alkyl, ammonium or metal silicates; containing silica sols reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895
• CPC Class Codes: C04B 28/344 the phosphate binder being present in the starting composition solely as one or more phosphates
• CPC Class Codes: C04B 38/08 by adding porous substances
• CPC Class Codes: C04B 38/10 by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C04B 40/00 Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02
• CPC Class Codes: C04B 7/00 Hydraulic cements calcium sulfate cements C04B11/00
• CPC Class Codes: Y10S 106/01 Fly ash
• CPC Class Codes: Y10S 106/02 Perlite

Abstract

A lightweight building material comprises expanded perlite as an additive and a bonding agent structure consisting of an alkalisilicate and containing pores formed by foaming and/or expansion. The pore content which results from the pore structure of the bonding agent amounts to 85 to 99% by volume, with bulk densities of 40 to 200 kg/m³, and strengths of 0.01 to 0.5 N/mm². In a method for producing a lightweight building material mortar mixes of the following composition are used:

70 to 85% by volume of perlite (bulk density from 20 to 150 g/l. grain-size from 0 to 6 mm)

23.0 to 2.5% by volume of water-glass (38 degrees Be)

25.0 to 5.0% by volume of water

1.0 to 0.10% by volume of hardener

2.0 to 0.05% by volume of air-entrainer.

Claims

1. A lightweight building material, comprising an additive having from 70 to 85 volume percent of expanded perlite and having bulk density from 20 to 150 g/l and grain size from 0 to 6 mm, a bonding agent structure composed of from 2.5 to 23 volume percent of water glass, and from 0.1 to 1.0 volume percent of hardener, the bonding agent structure is porous with the pore content of between 80 and 99 percent by volume, the lightweight building material having the bulk density between 40 and 200 kg/m³ and the strength between 0.01 and 0.5N/mm².

2. The building material as defined in claim 1, which is hydrophobic.

3. The building material as defined in claim 1, further including an additive selected from the group consisting of bentonite, kaolins, rice-husk ashes, fire-clay, wollastonite or other calcium silicates, kyanite or similar materials containing refractory clay, aluminum hydrate, clays, feldspar, feldspar substitutes, rock-granules, basalts, pegmatites, quarz-granules, silicic acid products with high specific surfaces, pumice and pumioite.

4. The building material as defined in claim 3, which further comprises hydraulic or latent hydraulic natural or synthetic products selected from the group consisting of cements, hydraulic limes, metallurgical sand, trass, porous volcanic tuft, gypsum and finely divided limestone.

5. A method for producing a lightweight building material, comprising the steps of mixing an additive having from 70 to 85 volume percent of expanded perlite and having bulk density 20 to 150 g/l and grain size from 0 to 6 mm, a bonding agent composed of 2.5 to 23 volume percent of water glass, 0.1 to 1.0 volume percent of hardener and 2.0 to 0.05 weight percent of air entrainer surfactant to produce a mortar mix, and allowing the mortar mix to set to form the building material.

6. The method as defined in claim 5, wherein the perlite in said additive is partially replaced by vermiculite and/or expanded clay and/or foamed glass.

7. The method as defined in claim 5, wherein an additive selected from the group consisting of bentonite, kaolin, rice-husk ashes, fire-clay, wollastonite or other calcium silicates, kyanite or similar materials containing refractory clay, aluminum hydrate, clays, feldspar, feldspar substitutes, rock-granules, basalts, pegmatites, quarz-granules and silicic acid products with high specific surfaces, pumice and pumioite is added to the mortar mix.

8. The method as defined in claim 6, wherein an additive selected from the group consisting of bentonite, kaolin, rice-husk ashes, fire-clay, wollastonite or other calcium silicates, kyanite or similar materials containing refractory clay, aluminum hydrate, clays, feldspar, feldspar substitutes, rock-granules, basalts, pegmatites, quarz-granules and silicic acid products with high specific surfaces, pumice and pumioite is added to the mortar mix.

9. The method as defined in claim 5, wherein said air-entrainer surfactant is an anionic surfactant having interfacial activity properties.

10. The method as defined in claim 9, wherein said air entrainer surfactant is a mixture of alkanesulphonate and hydroxyalkene-sulphonate.

11. The method as defined in claim 5, wherein said air-entrainer surfactant is α

-olefinsulphonate.

12. The method as defined in claim 5, wherein said air entrainer surfactant is sodium-oleytauride.

13. The method as defined in claim 5, wherein said hardener is K₂ SiF₆.

14. The method as defined in claim 5, wherein said hardener is CO₂ gas or a CO₂ -releasing substance.

15. The method as defined in claim 13, wherein heat is applied for hardening said hardener.

16. The method as defined in claim 14, wherein heat is applied for hardening said hardener.

17. The method as defined on claim 5, wherein the mortar mix is lightly stirred in order to activate said air entrainer surfactant.

18. The method as defined in claim 17, wherein the water glass and the air entrainer surfactant are added separately to the mix.

19. The method as defined in claim 18, wherein at least two preliminary separate mixes are made, one mix including the water-glass and the other mix including the air-entrainer surfactant, and the other mix being added the one mix when the foaming is to begin.

20. The method as defined in claim 19, wherein more than two separate preliminary mixes are made, one preliminary mix containing the water glass and the other preliminary mix containing the air-entrainer surfactant.

21. The method as defined in claim 19 wherein a surface of the hardened lightweight building material is made hydrophobic by a hydrophobic agent.

22. The method as defined in claim 19, wherein a hydrophobic agent is added to a foamed mass, which already exhibits a completely foamed structure and is then distributed in the mass of the material whereupon hardening occurs directly.

23. The method as defined in claim 21, wherein said hydrophobic agent is selected from the group consisting of methylpolysiloxanes, silicone-oils, silicone-resin emulsions, fatty amines, fatty acids, fatty alcohols and stearates.

24. The method as defined in claim 22, wherein said hydrophobic agent is selected from the group consisting of methylpolysiloxanes, silicon-oils, silicone-resin emulsions, fatty amines, fatty acids, fatty alcohols and stearates.

25. A lightweight building material, comprising from 70 to 85 volume percent of additive including expanded perlite and vermiculite and having bulk density from 20 to 150 g/l and grain size from 0 to 6 mm, a bonding agent structure composed of from 2.5 to 23 volume percent of water glass, and from 0.1 to 1.0 volume percent of hardener, the bonding agent structure being porous with the pore content of between 80 and 99 percent by volume, the lightweight building material having the bulk density between 40 and 200 kg/m³ and the strength between 0.01 and 0.5N/mm².

26. A lightweight building material, comprising from 70 to 85 volume percent of additive including expanded perlite and expanded clay and having bulk density from 20 to 150 g/l and grain size from 0 to 6 mm, a bonding agent structure composed of from 2.5 to 23 volume percent of water glass, and from 0.1 to 1.0 volume percent of hardener, the bonding agent structure being porous with the pore content of between 80 and 99 percent by volume, the lightweight building material having the bulk density between 40 and 200 kg/m³ and the strength between 0.01 and 0.5N/mm².

27. A lightweight building material, comprising from 70 to 85 volume percent of additive including expanded perlite and foamed glass and having bulk density from 20 to 150 g/l and grain size from 0 to 6 mm, a bonding agent structure composed of from 2.5 to 23 volume percent of water glass, and from 0.1 to 1.0 volume percent of hardener, the bonding agent structure being porous with the pore content of between 80 and 99 percent by volume, the lightweight building material having the bulk density between 40 and 200 kg/m³ and the strength between 0.01 and 0.5 N/mm².

28. A lightweight building material, comprising from 70 to 85 volume percent of additive including expanded perlite, vermiculite, expanded clay and foamed glass and having bulk density from 20 to 150 g/l and grain size from 0 to 6 mm, a bonding agent structure composed of from 2.5 to 23 volume percent of water glass, and from 0.1 to 1.0 volume percent of hardener, the bonding agent structure being porous with the pore content of between 80 and 99 percent by volume, the lightweight building material having the bulk density between 40 and 200 kg/m³ and the strength between 0.01 and 0.5 N/mm².