WO1992002468A1 - Method for producing lightweight aggregates, adhesive composition for implementing same, and aggregates thereby obtained - Google Patents

Method for producing lightweight aggregates, adhesive composition for implementing same, and aggregates thereby obtained Download PDF

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Publication number
WO1992002468A1
WO1992002468A1 PCT/CH1991/000157 CH9100157W WO9202468A1 WO 1992002468 A1 WO1992002468 A1 WO 1992002468A1 CH 9100157 W CH9100157 W CH 9100157W WO 9202468 A1 WO9202468 A1 WO 9202468A1
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WIPO (PCT)
Prior art keywords
aggregates
light
bitumen
weight
mixture
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PCT/CH1991/000157
Other languages
French (fr)
Inventor
Bernard Ansaloni
Pierre-Alain Daverio
Eric Schnell
Georges Sol
Original Assignee
Bernard Ansaloni
Daverio Pierre Alain
Eric Schnell
Georges Sol
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Application filed by Bernard Ansaloni, Daverio Pierre Alain, Eric Schnell, Georges Sol filed Critical Bernard Ansaloni
Publication of WO1992002468A1 publication Critical patent/WO1992002468A1/en

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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
    • 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
    • C04B20/12—Multiple coating or impregnating
    • 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
    • C04B28/04—Portland cements

Definitions

  • the invention relates to a process for manufacturing light aggregates as well as the aggregates obtained by this process.
  • the invention relates to a process for manufacturing light aggregates constituted by agglomerates comprising each comprising a central part, made of microporous light material, covered on at least part of its surface, by at least one layer of material coating consisting of sand or hydraulic binder, or a mixture thereof, according to which an adhesive substance, in the liquid or pasty state, is applied to the surface of the body in light microporous material, so as to cover at least part of this surface with this substance, and the bodies thus covered with adhesive substance are mixed with said coating material, while keeping the whole under agitation, so as to cause adhesion of said coating material on the surface of said bodies.
  • the light aggregates obtained by this process are in particular intended to be used for the manufacture of concrete or light plaster or else to be used, as such, as an insulating filling material, or even to be incorporated in bitumen.
  • the lightweight concrete is t is obtained by replacing at least a portion of the usual aggregates with light aggregates consist of grains or blocks of microporous material, org u 'that or mineral, natural, artificial u synthetic having a density less than 1, such as expanded polystyrene.
  • the light aggregates can have very varied dimensions and shapes and can in particular be in the form of beads with a diameter of 0.1 to 50 mm.
  • Lightweight concretes are of great interest, both in the field of construction and in that of public works, because of their specific weight much lower than that of ordinary concretes, as well as their improved thermal and sound insulation properties compared to to those of the latter.
  • French patent application No. 75 28547 discloses a granulate manufacturing process consisting of expanded polystyrene beads, whose surface is entirely covered with a hard shell, dried and adh * r ⁇ nte , consisting of a powdery material such as crown, .., sand or plaster.
  • This process comprises an operation of coating the polystyrene beads with a "glue binder” based on synthetic resins, followed by kneading the beads thus coated with "glue binder” in a mixer where they receive said pulverulent material which, in incorporating the "glue binder", forms said shell, without agglutination of the aggregates between them.
  • this document gives no indication relating to the problem posed by the impossibility of using light aggregates in a concrete plant and, a fortiori, to a possible solution of this problem consisting in weighing the aggregates by covering all or part of their surface by a layer of sand and / or hydraulic binder, giving them a density suitable for such use.
  • German patent application published before examination (DOS No. 2 125 715, describes a process for manufacturing "light construction parts", in expanded polystyrene particles, according to which these particles are coated with an acidic aqueous emulsion of bitumen and the 'the particles thus treated are then put into a form allowing their use by "overcoming their hydrophobic character", for example by dusting with powdered limestone.
  • US Patent No. 4,547,331 describes a process for manufacturing articles, in particular light concrete building blocks.
  • expanded polystyrene beads are mixed with a binder consisting, for example, of a mixture of bitumen, bitumen oil and epoxy resin, so as to form a sticky mass to which dry cement is then added, which makes it possible to obtain particles individually coated with a layer of cement and, finally, the particles are used thus obtained to form lightweight concrete blocks by adding an additional quantity of cement and water.
  • a binder consisting, for example, of a mixture of bitumen, bitumen oil and epoxy resin
  • the invention aims to provide a solution to the problem of the inhomogeneity of the distribution of light aggregates in concrete, which does not have the drawbacks of the solutions proposed according to the prior art.
  • the invention also aims to allow the obtaining of light aggregates of very low density suitable for use in the industrial manufacture of concrete in large capacity installations, such as concrete plants.
  • the method according to the invention is characterized in that said adhesive substance consists essentially of a mixture of an acidic aqueous emulsion of bitumen and latex.
  • the aggregates obtained by this process are characterized in that the density of said light, microporous material has a value of 0.005 to 0.015 and the overall density of the aggregates has a value of 0.085 to 0.225.
  • microporous light material which constitutes the central core of the composite agglomerates
  • any suitable material can be used, in particular one of those currently used as light or super-light aggregate.
  • one of the following materials can be used: light schist or clay rocks, pumice, pozzolans, expanded glass, perlites, vermiculites, wood, cork, charcoal, polyurethane foam, expanded polyvinyl chloride, expanded polystyrene .
  • microporous light material expanded polystyrene, in particular the material manufactured by the company BASF and marketed under the name of "STYROPOR".
  • the light microporous material is a recovery product from industrial or household waste.
  • said material such as packaging material waste
  • the pieces or grains of light microporous material can be of any shape, regular or irregular, for example spherical, ovoid, polyhedral or cylindrical, and their particle size is preferably between 0.1 and 30 mm.
  • sand As sand, it is possible in particular to use sands of basaltic, metamorphic or eruptive rocks, this sand being of alluvial origin or originating from rock crushing and preferably having a particle size of 0.1 to 5 mm.
  • the granulometry of the sand used is advantageously chosen according to the dimensions of the pieces. or grains of the light microporous material which constitutes the central core of the agglomerates.
  • the ratio of the maximum dimensions of the grains of sand to those of the pieces of light microporous material is of the order of 0.25 to 0.5. It is possible to use sand made up of several fractions of different particle sizes.
  • hydraulic binder one can use any artificial or natural cement suitable for the manufacture of concrete, in particular Portland cement, or also lime, plaster, or a mixture of cement and lime.
  • the mixture of acidic aqueous emulsion of bitumen and latex which constitutes the new product used as adhesive substance according to the invention, can be obtained by hot emulsifying emulsifiable bitumen (for example bitumen, consisting of a by-product petroleum distillation, having a penetration value of 180 to 220) in the presence of water, at least one mineral acid such as hydrochloric acid and an emulsification aid based on amine, then in mixing the emulsion thus obtained with a latex, in particular a synthetic latex (aqueous emulsion of a synthetic elastomeric resin).
  • emulsifiable bitumen for example bitumen, consisting of a by-product petroleum distillation, having a penetration value of 180 to 220
  • at least one mineral acid such as hydrochloric acid and an emulsification aid based on amine
  • the process is preferably carried out by intimately mixing, continuously by pressure turbination, bitumen heated to an appropriate temperature of the order of 120 ° C. and water previously brought to a temperature of approximately 60 ° C., in weight proportions of approximately 60 to 70%, of bitumen for 30 to 40% of water, in the presence of an aqueous solution of mineral acid and of emulsifying adjuvant.
  • the proportions of bitumen emulsion and of latex in this adhesive substance are of the order of 80 to 97% by weight of bitumen emulsion for 3 to 20% by weight of latex.
  • any suitable device or apparatus such as a mixer or granulation plate, or a combination of several different devices, for example a combination of mixer or granulation plate with a device for spraying liquid adhesive material onto particles of light microporous material maintained with vigorous stirring , for example in a fluidized bed.
  • the specific weight of the composite agglomerates constituting the aggregates according to the invention is of the order of 85 to 225 kg / m3.
  • the invention also relates to the use of aggregates for the manufacture of light concrete, this use being characterized by the fact that the aggregates are mixed homogeneously with a suitable quantity of cement. hydraulic and water.
  • the invention makes it possible to obtain a concrete having a specific weight of the order of 200 to 250 kg / m3, such concrete being, consequently, significantly lighter than the so-called "super-light” concretes currently known, the specific weight is at least 500 kg / m3.
  • the present invention allows the industrial manufacture of light concrete by using, as starting material, a microporous light material having a density well below the lower limit of the density values of the light materials usable for the industrial manufacture of lightweight concrete according to the prior art. This results in a significant reduction in the cost price of the raw materials used in the manufacture of concrete.
  • Agglomerates are made up of a spherical central core in expanded polystyrene, coated with sand, from the following materials:
  • Expanded polystyrene beads (density: 0.008)
  • Silicon sand (density: 1.6) with a particle size between 0.5 and 5 mm: 150 kg
  • Liquid adhesive material obtained by diluting, in 3 l of water, 4 kg of a mixture of 90 parts by weight of acidic aqueous er jlsion of bitumen, at 65% by weight of bitumen, and 10 parts by weight of latex synthetic) 7 kg.
  • the acidic aqueous bitumen emulsion is obtained by turbinating, at high speed, a mixture of bitumen heated to 120 ° C and water heated to 60 ° C in proportions of 65% by weight of bitumen for 35% by weight of water, in the presence of 1.5 kg of hydrochloric acid and 7 kg of amine-based emulsifying adjuvant (product marketed under the name of "Emulsamine L 60") per tonne of emulsion, producing continuously mixing and turbining operations.
  • the expanded polystyrene beads and the liquid adhesive material are mixed in a kneader, for approximately 20 seconds, then the sand is introduced while continuing the kneading, and the agglomerates are obtained in the state dry after a total preparation time of about 1 minute.
  • the agglomerates thus obtained have a specific weight of 165 kg / m3 and they are perfectly suitable for the preparation of a lightweight concrete in a concrete plant that has not undergone any particular transformation, by simple mixing with a suitable quantity of Portland cement and water, possibly adding an additional quantity of sand or gravel depending on the desired concrete composition.
  • Aggregates are made up of a spherical central core of expanded polystyrene coated with a layer of hardened cement, proceeding in the same manner as in Example 1 but using 25 kg of Portland cement instead of sand. per cubic meter of polystyrene beads.
  • Example 4 The operations of Example 4 are repeated, replacing the polystyrene beads with the aggregates obtained according to Example 4, so as to obtain aggregates coated with a double layer of hardened cement.
  • the aggregates obtained according to Examples 4 and 5 can be used, either for the manufacture of lightweight concrete, or as such, as a filling or insulation material.
  • aggregates can also be used in the state partially or entirely coated in pure bitumen or in an aqueous bitumen emulsion.
  • the aggregates can also be used in the state partially or entirely coated in pure bitumen or in an aqueous bitumen emulsion.

Abstract

An adhesive substance, consisting of a mixture of latex and an acidic aqueous bitumen emulsion, is applied on the surface of expanded polystyrene bodies, whereafter the bodies thereby coated with the adhesive substance are stirred into sand or a sand/cement mixture. The resulting aggregates have a relative density of 0.085 - 0.225 and consist of composite pellets each having a central expanded polystyrene portion at least partially coated with sand or sand and cement. These aggregates are suitable for the industrial manufacture of lightweight concrete in high-capacity installations such as concrete mixing plants.

Description

PROCEDE DE FABRICATION DE GRANULATS LEGERS, COMPOSITION ADHESIVE POUR SA MISE EN OEUVRE ET GRANULATS OBTENUS PAR CE PROCEDE PROCESS FOR THE MANUFACTURE OF LIGHT AGGREGATES, ADHESIVE COMPOSITION FOR ITS IMPLEMENTATION AND AGGREGATES OBTAINED BY THIS PROCESS
Domaine technique :Technical area :
L'invention concerne un procédé de fabrication de granulats légers ainsi que les granulats obtenus par ce procédé.The invention relates to a process for manufacturing light aggregates as well as the aggregates obtained by this process.
Plus précisément, l'invention porte sur un procédé de fabrication de granulats légers constitués par des agglomérats compor tes comprenant chacun une partie centrale, en matière légère microporeuse, recouverte sur au moins une partie de sa surface, par au moins une couche de matière d'enrobage constituée de sable ou de liant hydraulique, ou de leur mélange, selon lequel on applique une substance adhésive, à l'état liquide ou pâteux sur la surface de corps en matière légère microporeuse, de façon à recouvrir au moins une partie de cette surface par cette substance, et l'on mélange les corps ainsi recouverts de substance adhésive avec ladite matière d'enrobage, en maintenant le tout sous agitation, de façon à provoquer l'adhésion de ladite matière d'enrobage sur la surface desdits corps.More specifically, the invention relates to a process for manufacturing light aggregates constituted by agglomerates comprising each comprising a central part, made of microporous light material, covered on at least part of its surface, by at least one layer of material coating consisting of sand or hydraulic binder, or a mixture thereof, according to which an adhesive substance, in the liquid or pasty state, is applied to the surface of the body in light microporous material, so as to cover at least part of this surface with this substance, and the bodies thus covered with adhesive substance are mixed with said coating material, while keeping the whole under agitation, so as to cause adhesion of said coating material on the surface of said bodies.
Les granulats légers obtenus par ce procédé sont notamment destinés à être utilisés pour la fabrication du béton ou de plâtre allégé ou bien à être employés, tels quels, comme matériau de remplissage isolant, ou encore à être incorporés dans du bitume.The light aggregates obtained by this process are in particular intended to be used for the manufacture of concrete or light plaster or else to be used, as such, as an insulating filling material, or even to be incorporated in bitumen.
Comme on le sait, le béton allégé est un t on obtenu en remplaçant au moins une partie des granulats habituels par des granulats légers constitués par des grains ou blocs de matière microporeuse, org u'que ou minérale, naturelle, artificielle ' u synthétique, ayant une densité inférieure à 1 , telle que le polystyrène expansé. Les granulats légers peuvent avoir des dimensions et des formes très variées et être notamment sous forme de billes d'un diamètre de 0,1 à 50 mm.As is known, the lightweight concrete is t is obtained by replacing at least a portion of the usual aggregates with light aggregates consist of grains or blocks of microporous material, org u 'that or mineral, natural, artificial u synthetic having a density less than 1, such as expanded polystyrene. The light aggregates can have very varied dimensions and shapes and can in particular be in the form of beads with a diameter of 0.1 to 50 mm.
Les bétons allégés présentent un grand intérêt, aussi bien dans le domaine du bâtiment que dans celui des travaux publics, en raison de leur poids spécifique très inférieur à celui des bétons ordinaires, ainsi que de leurs propriétés d'isolation thermique et phonique améliorées par rapport à celles de ces derniers.Lightweight concretes are of great interest, both in the field of construction and in that of public works, because of their specific weight much lower than that of ordinary concretes, as well as their improved thermal and sound insulation properties compared to to those of the latter.
Il est toutefois difficile d'obtenir des bétons légers dans lesquels la répartition des granulats légers est homogène. En effet, lors de la préparation du béton, la différence entre la densité de ces granulats et celle des autres matières premières utilisées pour cette préparation provoque un phénomène de ségrégation qui est, bien entendu, d'autant plus marqué que cette différence est importante.It is however difficult to obtain light concretes in which the distribution of the light aggregates is homogeneous. Indeed, during the preparation of concrete, the difference between the density of these aggregates and that of the other raw materials used for this preparation causes a phenomenon of segregation which is, of course, all the more marked as this difference is important.
Technique antérieure :Prior art:
Afin d'éviter cette ségrégation, ou tout au moins de la limiter, il est connu d'incorporer divers adjuvants dans l'eau de gâchage du béton ou bien dans le ciment, ou encore de soumettre les granulats légers, avant leur mélange avec les autres matières premières de la préparation du béton, à un traitement de surface destiné à améliorer leur aptitude à se mélanger avec lesdites matières premières. Un tel traitement de surface est décrit dans le brevet européen No 0 185 583.In order to avoid this segregation, or at least to limit it, it is known to incorporate various additives in the mixing water of the concrete or in the cement, or else to subject the light aggregates, before their mixing with the other raw materials from concrete preparation, to a surface treatment intended to improve their ability to mix with said raw materials. Such a surface treatment is described in European patent No. 0 185 583.
Cependant, les mesures ainsi prises, conformément à l'art antérieur, n'apportent pas de solution pleinement satisfaisante au problème de l'inhomogénéité de la répartition des agrégats légers dans le béton. D'autre part, il n'était pratiquement pas possible, jusqu'à présent, d'utiliser des granulats légers ayant une très faible densité, à savoir de l'ordre de 0,008 à 0,015, environ, pour la fabrication industrielle du béton dans des installations de grande capacité de production du type dit "centrale à béton".However, the measures thus taken, in accordance with the prior art, do not provide a fully satisfactory solution to the problem of the inhomogeneity of the distribution of light aggregates in concrete. On the other hand, it has been practically impossible, until now, to use light aggregates having a very low density, namely of the order of about 0.008 to 0.015, for the industrial manufacture of concrete in large capacity production facilities of the so-called "concrete plant" type.
En effet, outre le problème posé par le phénomène de ségrégation mentionné plus haut, la trop faible densité des granulats ne permet pas de procéder à leur dosage par pesée, et oblige d'avoir recours à des dispositifs de dosage volumétrique, ce qui implique la nécessité de modifier, de manière importante, l'agencement des centrales à béton qui sont conçues pour l'utilisation de granulats ayant une densité de l'ordre de 1 ,4 à 1 ,65.Indeed, in addition to the problem posed by the segregation phenomenon mentioned above, the too low density of the aggregates does not allow them to be weighed, and requires the use of volumetric dosing devices, which implies the need to significantly modify the layout of concrete batching plants which are designed for the use of aggregates with a density on the order of 1.4 to 1.65.
En outre, les granulats légers de très faible densité se prêtent très mal au transport vers les trémies de mélange et les cuves de malaxage au moyen des dispositifs usuels, tels que les tapis roulants et les bandes convoyeuses, ainsi qu'à l'écoulement par gravité, et l'utilisation de tels granulats dans des centrales à béton entraînerait la nécessité d'avoir recours à des dispositifs complexes et mal adaptés aux centrales à béton, tels que des dispositifs de transport pneumatique dont l'installation entraînerait des frais de transformation considérâmes.In addition, light aggregates of very low density do not lend themselves very well to transport to the mixing hoppers and mixing tanks by means of the usual devices, such as conveyor belts and conveyor belts, as well as to the flow through. r gravity, and the use of such aggregates in concrete plants would entail the need to have recourse to complex devices which are poorly suited to concrete plants, such as pneumatic conveying devices whose installation would entail transformation costs considered.
La demande de brevet français No 75 28547 (publiée sous le No 2 324 589) décrit un procédé de fabrication de granulats constitués par des billes de polystyrène expansé, dont la surface est entièrement recouverte d'une coquille dure, sèche et adh*rβnte, consistant en une matière pulvérulente telle que du cime,.., du sable ou du plâtre.French patent application No. 75 28547 (Publication No. 2,324,589) discloses a granulate manufacturing process consisting of expanded polystyrene beads, whose surface is entirely covered with a hard shell, dried and adh * r βnte , consisting of a powdery material such as crown, .., sand or plaster.
Ce procédé comprend une opération d'enrobage des billes de polystyrène par un "liant-colle" à base de résines synthétiques, suivie du malaxage des billes ainsi enduites de "liant-colle" dans un mélangeur où elles reçoivent ladite matière pulvérulente qui, en s'incorporant au "liant-colle", forme ladite coquille, sans agglutination des granulats entre eux. Toutefois, ce document ne donne aucune indication relative au problème posé par l'impossibilité d'utiliser des granulats légers dans une centrale à béton et, a fortiori, à une éventuelle solution de ce problème consistant à alourdir les granulats par recouvrement de tout ou partie de leur surface par une couche de sable et/ou de liant hydraulique, en leur conférant une densité appropriée à une telle utilisation.This process comprises an operation of coating the polystyrene beads with a "glue binder" based on synthetic resins, followed by kneading the beads thus coated with "glue binder" in a mixer where they receive said pulverulent material which, in incorporating the "glue binder", forms said shell, without agglutination of the aggregates between them. However, this document gives no indication relating to the problem posed by the impossibility of using light aggregates in a concrete plant and, a fortiori, to a possible solution of this problem consisting in weighing the aggregates by covering all or part of their surface by a layer of sand and / or hydraulic binder, giving them a density suitable for such use.
D'autre part, l'utilisation de matière adhésive à base de résines synthétique ne se prête pas à une fabrication industrielle de tels granulats enrobés.On the other hand, the use of adhesive material based on synthetic resins does not lend itself to the industrial manufacture of such coated aggregates.
La demande de brevet allemand, publiée avant examen (DOS No 2 125 715, décrit un procédé de fabrication de "pièces de construction légères", en particules de polystyrène expansé, selon lequel on enrobe ces particules par une emulsion aqueuse acide de bitume et l'on met ensuite les particules ainsi traitées sous une forme permettant leur utilisation en "surmontant leur caractère hydrophobe", par exemple par saupoudrage par du calcaire en poudre.The German patent application, published before examination (DOS No. 2 125 715, describes a process for manufacturing "light construction parts", in expanded polystyrene particles, according to which these particles are coated with an acidic aqueous emulsion of bitumen and the 'the particles thus treated are then put into a form allowing their use by "overcoming their hydrophobic character", for example by dusting with powdered limestone.
D'autre part, il est indiqué dans ce document que l'on peut éventuellement ajouter une résine synthétique ou une dispersion de latex aux particules de polystyrène, préalablement enrobées de matière pulvérulente, afin de former une couche de protection contre le gel.On the other hand, it is indicated in this document that it is optionally possible to add a synthetic resin or a latex dispersion to the polystyrene particles, previously coated with pulverulent material, in order to form a layer of protection against frost.
Cependant, il n'est pas fait mention de l'utilisation d'un mélange d'émulsion aqueuse acide de bitume et de latex pour l'enrobage des particules de polystyrène par la matière pulvérulente.However, no mention is made of the use of a mixture of acidic aqueous emulsion of bitumen and latex for coating the polystyrene particles with the pulverulent material.
Le brevet US No 4.547.331 décrit un procédé de fabrication d'articles, notamment de blocs de construction en béton léger.US Patent No. 4,547,331 describes a process for manufacturing articles, in particular light concrete building blocks.
Selon ce procédé, des billes de polystyrène expansé sont mélangées avec un liant consistant, par exemple, en un mélange de bitume, d'huile de bitume et de résine epoxy, de façon à former une masse collante à laquelle on ajoute ensuite du ciment sec, ce qui permet l'obtention de particules individuellement revêtues d'une couche de ciment et, finalement, on utilise les particules ainsi obtenues pour former des blocs de béton léger par adjonction d'une quantité supplémentaire de ciment et d'eau.According to this process, expanded polystyrene beads are mixed with a binder consisting, for example, of a mixture of bitumen, bitumen oil and epoxy resin, so as to form a sticky mass to which dry cement is then added, which makes it possible to obtain particles individually coated with a layer of cement and, finally, the particles are used thus obtained to form lightweight concrete blocks by adding an additional quantity of cement and water.
Ce document ne donne également aucune indication concernant le problème de l'utilisation de granulats légers dans une centrale à béton, ni une éventuelle solution de ce problème.This document also does not give any indication concerning the problem of the use of light aggregates in a concrete plant, nor a possible solution of this problem.
Exposé de l'invention :Statement of the invention:
L'invention a pour but de permettre d'apporter une solution au problème de l'inhomogénéité de la répartition des granulats légers dans le béton, qui ne présentent pas les inconvénients des solutions proposées selon l'art antérieur.The invention aims to provide a solution to the problem of the inhomogeneity of the distribution of light aggregates in concrete, which does not have the drawbacks of the solutions proposed according to the prior art.
L'invention a également pour but de permettre l'obtenticn de granulats légers de très faible densité se prêtant à l'utilisation pour la fabrication industrielle du béton dans des installations de grande capacité, telles que des centrales à béton.The invention also aims to allow the obtaining of light aggregates of very low density suitable for use in the industrial manufacture of concrete in large capacity installations, such as concrete plants.
A cet effet, le procédé selon l'invention est caractérisé en ce que ladite substance adhésive est essentiellement constituée par un mélange d'une emulsion aqueuse acide de bitume et de latex.To this end, the method according to the invention is characterized in that said adhesive substance consists essentially of a mixture of an acidic aqueous emulsion of bitumen and latex.
Les granulats obtenus par ce procédé sont caractérisés en ce que la densité de ladite matière légère, microporeuse, a une valeur de 0,005 à 0,015 et la densité globale des granulats a une valeur de 0,085 à 0,225. Description de la misa n oeuvre de l'inventionThe aggregates obtained by this process are characterized in that the density of said light, microporous material has a value of 0.005 to 0.015 and the overall density of the aggregates has a value of 0.085 to 0.225. Description of the work of the invention
Comme matière légère microporeuse, qui constitue le noyau central des agglomérats composites, on peut utiliser toute matière appropriée, notamment l'une de celles qui sont actuellement employées comme granulat léger ou super-léger. En particulier, on peut utiliser l'une des matières suivantes: roches légères schisteuses ou argileuses, pierre ponce, pouzzolanes, verre expansé, perlites, vermiculites, bois, liège, charbon de bois, mousse de polyurethane, chlorure de polyvinyle expansé, polystyrène expansé.As microporous light material, which constitutes the central core of the composite agglomerates, any suitable material can be used, in particular one of those currently used as light or super-light aggregate. In particular, one of the following materials can be used: light schist or clay rocks, pumice, pozzolans, expanded glass, perlites, vermiculites, wood, cork, charcoal, polyurethane foam, expanded polyvinyl chloride, expanded polystyrene .
Avantageusement, on peut utiliser, comme matière légère microporeuse, le polystyrène expansé, notamment le matériau fabriqué par la société BASF et commercialisé sous le nom de "STYROPOR".Advantageously, it is possible to use, as microporous light material, expanded polystyrene, in particular the material manufactured by the company BASF and marketed under the name of "STYROPOR".
Avantageusement, la matière légère microporeuse est un produit de récupération provenant de déchets industriels ou ménagers. Dans ce cas, ladite matière, telle que des déchets de matière d'emballage, peut avantageusement être soumise à tout traitement approprié, tel qu'un lavage, un broyage, etc., qui peut être effectué, en combinaison ou après sa séparation du reste éventuel d'une masse de déchets industriels ou ménagers, de manière connue en soi.Advantageously, the light microporous material is a recovery product from industrial or household waste. In this case, said material, such as packaging material waste, can advantageously be subjected to any suitable treatment, such as washing, grinding, etc., which can be carried out, in combination or after its separation from the possible remainder of a mass of industrial or household waste, in a manner known per se.
Les morceaux ou grains de matière légère microporeuse peuvent être de forme quelconque, régulière ou irrégulière, par exemple sphérique, ovoïde, polyédrique ou cylindrique, et leur granulométrie est, de préférence, comprise entre 0,1 et 30 mm.The pieces or grains of light microporous material can be of any shape, regular or irregular, for example spherical, ovoid, polyhedral or cylindrical, and their particle size is preferably between 0.1 and 30 mm.
Comme sable, on peut notamment utiliser des sables de roches basaltiques, métamorphiques ou éruptives, ce sable étant d'origine alluvionnaire ou provenant du concassage de roches et ayant, de préférence, une granulométrie de 0,1 à 5 mm.As sand, it is possible in particular to use sands of basaltic, metamorphic or eruptive rocks, this sand being of alluvial origin or originating from rock crushing and preferably having a particle size of 0.1 to 5 mm.
Bien entendu, la granulométrie du sable utilisé est avantageusement choisie en fonction des dimensions des morceaux ou grains de la matière légère microporeuse qui constitue le noyau central des agglomérats. De préférence, le rapport des dimensions maximales des grains de sable à celles des morceaux de matière légère microporeuse est de l'ordre de 0,25 à 0,5. On peut utiliser du sable constitué de plusieurs fractions de granulométries différentes.Of course, the granulometry of the sand used is advantageously chosen according to the dimensions of the pieces. or grains of the light microporous material which constitutes the central core of the agglomerates. Preferably, the ratio of the maximum dimensions of the grains of sand to those of the pieces of light microporous material is of the order of 0.25 to 0.5. It is possible to use sand made up of several fractions of different particle sizes.
Comme liant hydraulique, on peut utiliser tout ciment artificiel ou naturel convenant pour la fabrication du béton, notamment du ciment Portland, ou encore de la chaux, du plâtre, ou un mélange de ciment et de chaux.As hydraulic binder, one can use any artificial or natural cement suitable for the manufacture of concrete, in particular Portland cement, or also lime, plaster, or a mixture of cement and lime.
On peut obtenir le mélange d'émulsion aqueuse acide de bitume et de latex, qui constitue le nouveau produit utilisé comme substance adhésive conformément à l'invention, en émulsifiant à chaud du bitume émulsifiable (par exemple du bitume, constitué par un sous- produit de distillation du pétrole, ayant une valeur de pénétration de 180 à 220) en présence d'eau, d'au moins un acide minéral tel que l'acide chlorhydrique et d'un adjuvant d'émulsification à base d'aminé, puis en mélangeant Pémulsion ainsi obtenue avec un latex, notamment un latex synthétique (emulsion aqueuse d'une résine élastomère synthétique).The mixture of acidic aqueous emulsion of bitumen and latex, which constitutes the new product used as adhesive substance according to the invention, can be obtained by hot emulsifying emulsifiable bitumen (for example bitumen, consisting of a by-product petroleum distillation, having a penetration value of 180 to 220) in the presence of water, at least one mineral acid such as hydrochloric acid and an emulsification aid based on amine, then in mixing the emulsion thus obtained with a latex, in particular a synthetic latex (aqueous emulsion of a synthetic elastomeric resin).
Pour la préparation de l'émulsion de bitume, on procède, de préférence, en mélangeant intimement par turbinage sous pression, en continu, du bitume chauffé à une température appropriée de l'ordre de 120° C et de l'eau préalablement portée à une température de 60° C environ, en proportions pondérales de 60 à 70% environ, de bitume pour 30 à 40% d'eau, en présence d'une solution aqueuse d'acide minéral et d'adjuvant d'émulsification.For the preparation of the bitumen emulsion, the process is preferably carried out by intimately mixing, continuously by pressure turbination, bitumen heated to an appropriate temperature of the order of 120 ° C. and water previously brought to a temperature of approximately 60 ° C., in weight proportions of approximately 60 to 70%, of bitumen for 30 to 40% of water, in the presence of an aqueous solution of mineral acid and of emulsifying adjuvant.
De préférence, les proportions d'émulsion de bitu ne et de latex dans cette substance adhésive sont de l'ordre de 80 à 97% en poids d'émulsion de bitume pour 3 à 20% en poids de latex.Preferably, the proportions of bitumen emulsion and of latex in this adhesive substance are of the order of 80 to 97% by weight of bitumen emulsion for 3 to 20% by weight of latex.
Pour la mise en oeuvre du procédé de fabrication des granulats, on peut utiliser tout dispositif ou appareil approprié, tel qu'un malaxeur ou une assiette de granulation, ou encore une combinaison de plusieurs appareils différents, par exemple une combinaison de malaxeur ou assiette de granulation avec un dispositif permettant d'effectuer une pulvérisation de matière adhésive liquide sur des particules de matière légère microporeuse maintenues sous agitation énergique, par exemple dans un lit fluidisé.For the implementation of the aggregates manufacturing process, any suitable device or apparatus, such as a mixer or granulation plate, or a combination of several different devices, for example a combination of mixer or granulation plate with a device for spraying liquid adhesive material onto particles of light microporous material maintained with vigorous stirring , for example in a fluidized bed.
De préférence, le poids spécifique des agglomérats composites constituant les granulats selon l'invention est de l'ordre de 85 à 225 kg/m3.Preferably, the specific weight of the composite agglomerates constituting the aggregates according to the invention is of the order of 85 to 225 kg / m3.
L'invention concerne également l'utilisation des granulats pour la fabrication d'un béton léger, cette utilisation étant caractérisée par le fait que l'on mélange, de manière homogène, les granulats avec une quantité convenable de ciment. hydraulique et d'eau.The invention also relates to the use of aggregates for the manufacture of light concrete, this use being characterized by the fact that the aggregates are mixed homogeneously with a suitable quantity of cement. hydraulic and water.
Bien entendu, on peut éventuellement incorporer, également dans le mélange de granulats selon l'invention de ciment hydraulique et d'eau, une certaine quantité de sable ainsi que de granulats ordinaires, par exemple des granulats roulés ou concassés.Of course, one can optionally incorporate, also in the mixture of aggregates according to the invention of hydraulic cement and water, a certain amount of sand as well as ordinary aggregates, for example rolled or crushed aggregates.
L'invention permet d'obtenir un béton ayant un poids spécifique de l'ordre de 200 à 250 kg/m3, un tel béton étant, par conséquent, nettement plus léger que les bétons dits "super-légers" actuellement connus, dont le poids spécifique est d'au moins 500 kg/m3.The invention makes it possible to obtain a concrete having a specific weight of the order of 200 to 250 kg / m3, such concrete being, consequently, significantly lighter than the so-called "super-light" concretes currently known, the specific weight is at least 500 kg / m3.
Il est à noter que la présente invention permet la fabrication industrielle du béton léger en utilisant, comme matériau de départ, une matière légère microporeuse ayant une densité bien au dessous de la limite inférieure des valeurs de densités des matières légères utilisables pour la fabrication industrielle de béton léger selon l'art antérieur. Ceci se traduit par une importante réduction du prix de revient des matières premières entrant dans la fabrication du béton. Exemple 1It should be noted that the present invention allows the industrial manufacture of light concrete by using, as starting material, a microporous light material having a density well below the lower limit of the density values of the light materials usable for the industrial manufacture of lightweight concrete according to the prior art. This results in a significant reduction in the cost price of the raw materials used in the manufacture of concrete. Example 1
On fabrique des agglomérats constitués d'un noyau central sphérique en polystyrène expansé, enrobé de sable, à partir des matériaux suivants:Agglomerates are made up of a spherical central core in expanded polystyrene, coated with sand, from the following materials:
Billes de polystyrène expansé (densité: 0,008)Expanded polystyrene beads (density: 0.008)
(mélange de billes ayant un diamètre variant entre 1 et 8 mm) 8 kg(mixture of balls with a diameter varying between 1 and 8 mm) 8 kg
Sable silicieux (densité: 1 ,6) de granulométrie comprise entre 0,5 et 5 mm : 150 kgSilicon sand (density: 1.6) with a particle size between 0.5 and 5 mm: 150 kg
Matière adhésive liquide (obtenue en diluant, dans 3 I d'eau, 4 kg d'un mélange de 90 parties en poids d'ér jlsion aqueuse acide de bitume, à 65% en poids de bitume, et 10 parties en poids de latex synthétique) 7 kg.Liquid adhesive material (obtained by diluting, in 3 l of water, 4 kg of a mixture of 90 parts by weight of acidic aqueous er jlsion of bitumen, at 65% by weight of bitumen, and 10 parts by weight of latex synthetic) 7 kg.
On obtient l'émulsion aqueuse acide de bitume en turbinant, à grande vitesse, un mélange de bitume chauffé à 120° C et d'eau chauffée à 60° C en proportions de 65% en poids de bitume pour 35% en poids d'eau, en présence de 1 ,5 kg d'acide chlorhydrique et 7 kg d'aojuvant d'émulsification à base d'aminé (produit commercialisé sous le nom de "Emulsamine L 60") par tonne d'émulsion, en réalisant en continu les opérations de mélange et de turbinage.The acidic aqueous bitumen emulsion is obtained by turbinating, at high speed, a mixture of bitumen heated to 120 ° C and water heated to 60 ° C in proportions of 65% by weight of bitumen for 35% by weight of water, in the presence of 1.5 kg of hydrochloric acid and 7 kg of amine-based emulsifying adjuvant (product marketed under the name of "Emulsamine L 60") per tonne of emulsion, producing continuously mixing and turbining operations.
Pour la préparation des agglomérats, on mélange d'abord les billes de polystyrène expansé et la matière adhésive liquide dans un malaxeur, pendant environ 20 secondes, puis on introduit le sable tout en continuant le malaxage, et on obtient les agglomérats à l'état sec au bout d'un temps total de préparation de l'ordre de 1 minute.For the preparation of the agglomerates, first the expanded polystyrene beads and the liquid adhesive material are mixed in a kneader, for approximately 20 seconds, then the sand is introduced while continuing the kneading, and the agglomerates are obtained in the state dry after a total preparation time of about 1 minute.
Les agglomérats ainsi obtenus ont un poids spécifique de 165 kg/m3 et ils conviennent parfaitement à la préparation d'un béton léger dans une centrale à béton n'ayant subi aucune transformation particulière, par simple mélange avec une quantité convenable de ciment Portland et d'eau, en ajoutant éventuellement une quantité supplémentaire de sable ou de gravier en fonction de la composition de béton désirée.The agglomerates thus obtained have a specific weight of 165 kg / m3 and they are perfectly suitable for the preparation of a lightweight concrete in a concrete plant that has not undergone any particular transformation, by simple mixing with a suitable quantity of Portland cement and water, possibly adding an additional quantity of sand or gravel depending on the desired concrete composition.
Exemple 2 :Example 2:
On procède de manière similaire à celle qui est décrite dans l'exemple 1 , mais en utilisant, à la place de sable, 150 kg de ciment Portland.The procedure is similar to that described in Example 1, but using 150 kg of Portland cement in place of sand.
Exemple 3 :Example 3:
On procède de la même manière que dans les exemples 1 et 2, mais en utilisant un mélange de 75 kg de sable et 75 kg de ciment Portland.The procedure is the same as in Examples 1 and 2, but using a mixture of 75 kg of sand and 75 kg of Portland cement.
Exemple 4 :Example 4:
On fabrique des granulats constitués d'un noyau central sphérique en polystyrène expansé enrobé d'une couche de ciment durci, en procédant de la même manière que dans l'exemple 1 mais en utilisant, à la place du sable, 25 kg de ciment Portland par mètre cube de billes de polystyrène.Aggregates are made up of a spherical central core of expanded polystyrene coated with a layer of hardened cement, proceeding in the same manner as in Example 1 but using 25 kg of Portland cement instead of sand. per cubic meter of polystyrene beads.
Exemple 5 :Example 5:
On répète les opérations de l'exemple 4, en remplaçant les billes de polystyrène par les granulats obtenus selon l'exemple 4, de façon à obtenir des granulats revêtus d'une double couche de ciment durci. On peut utiliser les granulats obtenus selon les exemples 4 et 5, soit pour la fabrication de béton allégé, soit tels quels, comme matériau de remplissage ou d'isolation.The operations of Example 4 are repeated, replacing the polystyrene beads with the aggregates obtained according to Example 4, so as to obtain aggregates coated with a double layer of hardened cement. The aggregates obtained according to Examples 4 and 5 can be used, either for the manufacture of lightweight concrete, or as such, as a filling or insulation material.
On peut également utiliser ces granulats à l'état partiellement ou entièrement enrobé dans du bitume pur ou dans une emulsion aqueuse de bitume. A cet effet, on peut réaliser l'incorporation des granulats dans le bitume ou l'émulsion de bitume "in situ", par exemple en appliquant directement une ou plusieurs couches pulvérulentes de granulats sur une surface, telle qu'une route, une terrasse, un toit-terrasse plat, ou encore la surface supérieure d'un pare-avalanche, puis en recouvrant cette couche, ou chacune de ces couches, par une couche de bitume ou d'émulsion de bitume, ou encore préparer un mélange de granulats et matière bitumineuse dans une centrale d'enrobage. These aggregates can also be used in the state partially or entirely coated in pure bitumen or in an aqueous bitumen emulsion. For this purpose, it is possible to incorporate the aggregates into the bitumen or the bitumen emulsion "in situ", for example by directly applying one or more powdery layers of aggregates on a surface, such as a road, a terrace. , a flat roof terrace, or the upper surface of an avalanche barrier, then covering this layer, or each of these layers, with a layer of bitumen or bitumen emulsion, or else prepare a mixture of aggregates and bituminous material in a coating plant.

Claims

REVENDICATIONS
1. Procédé de fabrication de granulats légers constitués par des agglomérats composites comprenant chacun une partie centrale, en matière légère microporeuse, recouverte sur au moins une partie de sa surface, par au moins une couche de matière d'enrobage constituée de sable ou de liant hydraulique, ou de leur mélange, selon lequel on applique une substance adhésive, à l'état liquide ou pâteux sur la surface de corps en matière légère microporeuse, de façon à recouvrir au moins une partie de cette surface par cette substance, et l'on mélange les corps ainsi recouverts de substance adhésive avec ladite matière d'enrobage, en maintenant le tout sous agitation, de façon à provoquer l'adhésion de ladite matière d'enrobage sur la surface desdits corps, caractérisé en ce que ladite substance adhésive est essentiellement constituée par un mélange d'une emulsion aqueuse acide de bitume et de latex.1. Method for manufacturing light aggregates consisting of composite agglomerates each comprising a central part, made of microporous light material, covered on at least part of its surface, by at least one layer of coating material made up of sand or binder hydraulic, or a mixture thereof, according to which an adhesive substance, in the liquid or pasty state, is applied to the surface of the body of light microporous material, so as to cover at least part of this surface with this substance, and the the bodies thus covered with adhesive substance are mixed with said coating material, while keeping the whole under stirring, so as to cause adhesion of said coating material on the surface of said bodies, characterized in that said adhesive substance is essentially constituted by a mixture of an acidic aqueous emulsion of bitumen and latex.
2. Procédé selon la revendication 1 , caractérisé en ce que la substance adhésive est constituée par un mélange de 80 à 97 parties en poids d'une emulsion d'eau dans le bitume, contenant 60 à 70% en poids de bitume et 30 à 40% en poids d'eau, et 3 à 20 parties en poids de latex.2. Method according to claim 1, characterized in that the adhesive substance consists of a mixture of 80 to 97 parts by weight of a water emulsion in bitumen, containing 60 to 70% by weight of bitumen and 30 to 40% by weight of water, and 3 to 20 parts by weight of latex.
3. Procédé selon la revendication 1 , caractérisé en ce que ledit liant hydraulique est constitué par au moins l'un des matériaux suivants: ciment hydraulique, chaux, plâtre, mélange de ciment et de chaux.3. Method according to claim 1, characterized in that said hydraulic binder consists of at least one of the following materials: hydraulic cement, lime, plaster, mixture of cement and lime.
4. Composition adhésive pour la mise en oeuvre du procédé selon la revendication 1 , caractérisée en ce qu'elle est essentiellement constituée par un mélange d'une emulsion aqueuse acide de bitume et de latex. 4. Adhesive composition for implementing the method according to claim 1, characterized in that it is essentially constituted by a mixture of an acidic aqueous emulsion of bitumen and latex.
5. Composition adhésive selon la revendication 4, caractérisée en ce qu'elle est constituée par un mélange de 80 à 97 parties en poids d'une emulsion d'eau dans le bitume, contenant 60 à 70% en poids de bitume et 30 à 40% en poids d'eau, et 3 à 20 parties en poids de latex.5. Adhesive composition according to claim 4, characterized in that it consists of a mixture of 80 to 97 parts by weight of a water emulsion in bitumen, containing 60 to 70% by weight of bitumen and 30 to 40% by weight of water, and 3 to 20 parts by weight of latex.
6. Granulats légers, obtenus par le procédé selon l'une des revendications 1 à 3, caractérisés en ce que la densité de ladite matière légère microporeuse a une valeur de 0,005 à 0,015, et la densité globale des granulats a une valeur de 0,085 à 0,225.6. Light aggregates, obtained by the method according to one of claims 1 to 3, characterized in that the density of said microporous light material has a value of 0.005 to 0.015, and the overall density of the aggregates has a value of 0.085 to 0.225.
7. Granulats selon la revendication 6, caractérisés en ce que ladite matière légère microporeuse est essentiellement constituée de polystyrène expansé.7. Aggregates according to claim 6, characterized in that said light microporous material consists essentially of expanded polystyrene.
8. Granulats selon la revendication 6 ou la revendication 7, caractérisés en ce que ladite matière légère microporeuse est un produit de récupération provenant de déchets industriels ou ménagers.8. Aggregates according to claim 6 or claim 7, characterized in that said light microporous material is a recovery product from industrial or household waste.
9. Utilisation des granulats selon l'une des revendications 6 à 8 pour la fabrication d'un béton léger, caractérisée par le fait que l'on mélange, de manière homogène, les granulats avec au moins un liant hydraulique et de l'eau ainsi que, le cas échéant, avec du sable et/ou du gravier.9. Use of aggregates according to one of claims 6 to 8 for the manufacture of light concrete, characterized in that the aggregates are mixed in a homogeneous manner with at least one hydraulic binder and water as well as, if necessary, with sand and / or gravel.
10. Béton léger obtenu par le procédé selon la revendication 9. 10. Lightweight concrete obtained by the process according to claim 9.
PCT/CH1991/000157 1990-08-03 1991-07-31 Method for producing lightweight aggregates, adhesive composition for implementing same, and aggregates thereby obtained WO1992002468A1 (en)

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ES2089931A1 (en) * 1992-08-10 1996-10-01 Alcaine Eduardo Diaz Improvements in a process for the manufacture of masses for the moulding of parts for construction
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WO2000004990A1 (en) * 1998-07-24 2000-02-03 John Rutherford Moody Agglomeration agent
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EP1130001A3 (en) * 2000-03-01 2003-01-29 Toray Industries, Inc. Aggregate, manufacturing process thereof and resin mortar containing this aggregate
US8329289B2 (en) 2006-06-09 2012-12-11 Omya Development Ag Composites of inorganic and/or organic microparticles and nano-calcium carbonate particles
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CN104193257A (en) * 2014-08-06 2014-12-10 南京市苏宝节能科技有限公司 Dry material applied to adhering exterior wall tiles
CN114315412A (en) * 2022-01-27 2022-04-12 西安建筑科技大学 Modified EPS particles, modification method thereof, concrete containing modified EPS particles and preparation method thereof
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