Concrete

• US 4,383,862 A
• Filed: 10/13/1981
• Issued: 05/17/1983
• Est. Priority Date: 10/11/1980
• Status: Expired due to Fees

• Current Assignee: SHAW Concrete Limited
• Original Assignee: Domocon SA
• Inventors: Dyson, John M.
• Primary Examiner(s): Poer, James
• Application Number:
  US06/310,940
• Time in Patent Office: 581 Days
• Field of Search: 106/86, 106/88, 106/97, 106/98
• US Class Current: 106/646
• CPC Class Codes: B28C 5/0875 Mixing in separate stages involving different containers for each stage
• CPC Class Codes: B28C 5/38 wherein the mixing is effected both by the action of a fluid and by directly-acting driven mechanical means, e.g. stirring means ; Producing cellular concrete
• CPC Class Codes: B28C 5/383 comprising stirrers to effect the mixing
• CPC Class Codes: B28C 7/165 using a fluid, e.g. gas B28C5/06, B28C5/1261 take precedence
• CPC Class Codes: C04B 28/04 Portland cements
• 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

Abstract

A method of producing aerated concrete, that is, concrete in which a gas is entrained, comprises forming a mortar mix, which includes all the components of the concrete except for the gas. The mix is then pumped at a predetermined rate, to blending means. Gas is fed under pressure to blending means via control valves.

The blending of the mix with the gas takes place in a substantially closed chamber.

Claims

1. A method for producing aerated concrete comprising the steps of:

(a) producing a mortar mix of water, sand, cement, a foaming agent and a silicate, said silicate being an active, colloidal silicate of magnesium, calcium, barium and/or aluminium prepared by precipitation from waterglass with a salt of the appropriate metal, and having a specific surface area in excess of 15 m² /gm as measured by the BET method and which is in the form of a hydrogel or a xerogel;

(b) pumping said mortar mix at a predetermined rate to a substantially closed chamber located within blending means;

(c) feeding gas via gas pressure regulation means to said chamber, thereby obtaining in said blending means mortar mix and gas in predetermined proportions; and

(d) blending said mortar mix and gas within said chamber by the action of a rotary mixer located within the chamber to produce aerated concrete mix which, when set, has a compressive strength of from 15 to 35 N/mm².

2. A method according to claim 1 wherein said blending means comprise a plurality of chambers, said chambers being arranged coaxially and such that the mortar mix flows sequentially through each of said chambers.

3. A method according to claim 1 in which said rotary mixer occupies substantially the entire space defined by the chamber, the mixer being substantially disc shaped but being provided with projections extending out of the plane of the disc on both sides thereof, said projections lying within recesses between projections extending from the walls of the or each chamber, such that on rotation of the mixer the projections thereon pass between the projections on the walls of the chambers thereby ensuring efficient blending of the mortar mix with the gas fed under pressure to the or each chamber.

4. A method according to claim 1 wherein the amount of silicate used is in the range of from 0.5% to 4% of the weight of the cement.

5. A method according to claim 1 wherein the amount of foaming agent is from 0.5% to 2% of the water content of the mortar.

6. A method according to claim 1 wherein the mortar mix further includes a sparingly soluble barium compound, the amount of said compound being from 0.05% to 2.5% by weight based on the weight of the cement.

7. A method according to claim 6 wherein the barium compound is added in an amount from 0.05% to 2.5% of the weight of the cement, said barium compound being a sparingly soluble barium compound of barium oxalate, barium fluoride or barium silicate hydrate having a BaO:

SiO₂ mole ratio of 0.5;

1.2;

1.