• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    This invention relates to a pourable concrete mortar suitable for forming a polishable concrete floor, comprising cement, sand, limestone and water, said sand being river sand having a particle size of less than 250 micrometers (µm) of up to 6% by weight. The undesirable effect of delamination is avoided by using such concrete mortar.
    公开号:BE1022343B1
    申请号:E2015/5057
    申请日:2015-02-06
    公开日:2016-03-25
    发明作者:Groote Bernard De
    申请人:Degroote Bernard Bvba；
    IPC主号:
    专利说明:

    PORTABLE CONCRETE FOR POLISHABLE CONCRETE FLOORS
    This invention relates on the one hand to a pourable concrete mortar suitable for forming a polable concrete floor. On the other hand, this invention relates to a method for forming such concrete mortar.
    In recent years, every concrete floor contractor is increasingly confronted with the undesirable occurrence of delamination with polished concrete floors. With this phenomenon, a thin layer of 3 to 10 mm separates. thick, in exceptional cases 30 mm., away from the concrete surface. This delamination can occur both immediately after the finish and a few days or months after the commissioning of the floor. The delaminated surface can be a few square centimeters to a few square meters. Delamination becomes visible when the surface of the hardened concrete starts to show damage during circulation.
    Delamination with polished concrete floors is probably caused by the fact that water (originating from the concrete) and air bubbles during polishing - due to the action of the screw blades of the polishing machine - migrate to the surface where they become trapped under the (meanwhile) more compact surface layer. This results in weaker zones where the surface layer can come loose due to the polishing, the use thereof or the shrinkage of the concrete.
    Chinese patent publication CN 101 786 850 describes a cementitious self-leveling mortar, the method of preparation and its use. The mortar in question comprises the following components: 31-40% by weight of cement, 13-15% by weight of plaster, 5-15% by weight of lime, 50-70% by weight of sand and additives. The sand that is used can be either quarter, river sand or industrial residue.
    The European patent publication EP 1 452 503 describes the composition of a self-leveling sludge that comprises the following components per cubic meter (m3): 320 kg. Portland cement, 400 kg. lime, 1352 kg of sand (0-2 mm. or 0 - 4 mm.) and gravel (2-8 mm. or 4 - 8 mm) and additives.
    The present invention has for its object to provide a pourable concrete mortar for the formation of polable concrete floors, which concrete mortar will greatly reduce and even prevent the risk of delamination of the polished concrete surface.
    The object of the invention is achieved by providing a pourable concrete mortar suitable for forming a polable concrete floor, comprising cement, sand, limestone and water, wherein said sand is river sand and that this river sand has a particle size of less than 250 micrometres (µm) of up to 6% by weight.
    To determine the particle size (or grain size) of the river sand, use can be made of the known technique called sieve analysis. The type of river sand used within the scope of this invention is preferably a round quartz sand 0/8 with the following specific characteristics: chloride content of <0.02% (m / m), shell content of <0.5% (m / m) m) and no presence of organic components. For comparison, a round sea sand 0/4 has a chloride content of <0.045%, shell content of <17% and always contains organic components.
    By using river sand, which is a coarser sand, than the sea sand used to date in such concrete compositions, one achieves a less viscous concrete mortar than the concrete mortar used to date for forming polable concrete floors. By using a less viscous concrete mortar, air bubbles and water can escape, as it were, before the surface is compacted. As a result, the water and the air bubbles no longer get trapped under the concrete surface, and delamination will therefore no longer occur.
    In a preferred embodiment of the concrete mortar according to the invention, the concrete mortar contains at least 309 kg / m3, preferably at least 320 kg / m3 of cement. Such a composition is particularly suitable for indoor applications. The amount of cement in the concrete mortar depends on the application, and is preferably between 309 kg / m3 and 393 kg / m3.
    In a more preferred embodiment of the concrete mortar according to the invention, the water (w) / cement (c) factor without absorption, of the said concrete mortar, is a maximum of 0.52. In particular, the water (w) / cement (c) factor with absorption of the said concrete mix is a maximum of 0.49.
    In an alternative embodiment of the concrete mortar according to the invention, the concrete mortar contains at least 370 kg / m3, preferably at least 380 kg / m3 of cement. Such a composition is particularly suitable for outdoor applications. With such concrete mortar, the water (w) / cement (c) factor without absorption, of the said concrete mortar, is a maximum of 0.44 and the water (w) / cement (c) factor with absorption, of the said concrete mortar, is a maximum of 0.41 .
    According to a special embodiment of the concrete mortar according to the invention, the concrete mortar contains at least 660 kg / m3, preferably at least 697 kg / m3 of river sand. These amounts are particularly suitable for indoor applications. For outdoor applications, approximately 708 kg / m3 of river sand will be added. The amount of river sand in the concrete mix depends on the application, and is preferably between 660 kg / m3 and 744 kg / m3.
    Another subject of this invention relates to a method for manufacturing a pourable concrete mortar suitable for forming a polishable concrete floor, wherein at least cement, water, limestone and river sand that has a particle size of less than 250 micrometers (µm) of at most 6 wt. % are mixed into a homogeneous concrete mix. By only using such river sand, a (vis-à-vis the known species for such applications) less viscous mortar is obtained, whereby the chance of delamination of the floor formed with it is greatly reduced or even excluded. Of course, other known additives or auxiliaries can also be added during the production of the mortar.
    The invention is explained below with reference to the following description and a number of elaborated examples. These examples are to be considered as an illustration of the invention and are not to be construed as limiting the scope of the invention.
    Concrete types suitable for forming polable concrete floors are produced exclusively with fine sea sand as standard. However, this fine sea sand in combination with PCE (polycarboxylates) superplast forms a sticky concrete. The disadvantage of sticky concrete is that the mixing water will migrate much slower to the surface where it will prevent premature dehydration of the concrete surface. This phenomenon of water separation is known within the concrete industry as "Weeding". Over time, the bleeding water is absorbed by the concrete, so that it always remains moist on the surface to work in the quartz layer during polishing. This quartz layer is also a dry matter and needs a certain percentage of water to be able to hydrate and attach to the underlying concrete. However, since the introduction of the stricter (BENOR) standards, with the emphasis on keeping the water / cement (w / c) factor low, in order to produce 'concrete on resistance' with a low shrinkage due to the low water content, a maximum water content was imposed on the concrete composition. Consequently, it is no longer possible to add water to ensure good adhesion in this way. To solve this and to keep the concrete mortar pumpable and processable, a so-called superplasticiser based on polycarboxylates (PCE) is added. Such PCE superplast causes a steric hindrance between the cement particles and has a delaying effect on the concrete. This, combined with insufficient water according to the content of fine material, causes the undesirable phenomenon of crusting.
    The formation of crusts manifests itself in the absence of separation water on an already hardened concrete surface, while the underlying concrete is still plastic. In practice, this means that when the concrete poliers notice that the concrete surface is drying out, they are obliged to start the infusion of the quartz material in order to be able to screw it into the concrete and to achieve the desired flatness. reach. However, as a result, the poliers experience the so-called mattress effect, whereby the vibrations of the polishing machines, the fine material, migrate to the concrete surface as the separation water, while the top layer is already compacted. These fine particles and water collect under the (compacted) top layer, resulting in the previously described delamination effect.
    To prevent this, a new concrete composition, specifically suitable for the formation of polishable floors, has been developed by the patent holder. This development came about on the basis of their own experiences, where they came to the conclusion that the two biggest aspects for facilitating delamination were the following: - a too low water content according to the dosage of fine sands; - a too high dosage of PCE superlasts, which in itself is necessary to maintain good workability of the concrete and to compensate for the shortage of water.
    Based on these findings, a specific concrete mix was developed using a specific coarse sand type with a perfect grain curve, in alignment with the cement content and the other granulates (limestone) in the concrete mix. More specifically, use is now made of river sand which has a particle size (grain size) of less than 250 micrometers (µm) of a maximum of 6% by weight. For comparison, the current concrete compositions for forming polable concrete floors are made with fine sea sands that have a fall-through at 250 μ of 15 to 20% by weight.
    By adjusting the concrete composition in that sense, a coarser mortar was obtained, so that the amount of superplast and other granulates (limestone) also had to be adjusted. Tests have now shown that the concrete mortar according to the invention requires 15 liters less water per cubic meter of concrete than if sea sand were used. In this way, and as will be apparent from the exemplary embodiments below, a concrete with more free water and a lower w / c factor is obtained than the concrete mortar known to date. In addition, in the concrete mortar specifically suitable for indoor use, a super plasticizer is no longer used when the concrete is produced at the concrete plant.
    Example 1
    To form a concrete floor in a covered area that still needs to be polished, lm3 pumpable polished concrete was made. The requirements (BENOR) for the concrete were: strength class: C25 / 30; environment class: EE2; consistency class: S3. Additional requirement: pump concrete, polier concrete, min. Compressive strength on cube of 33 N / mm 2 instead of 30 N / mm 2, min. 320 kg. cement, reinforced concrete.
    For this, the following raw materials in the quantities mentioned were used per cubic meter of concrete. Here, too, the lower limit and upper limit are always displayed within which the various raw materials can be added. In this example, no plasticizing auxiliaries (plasticizer or superplasticizer) were added.
    • 157 kg (152.29 kg - 161.71 kg) CEM IIEA 42.5 N LA
    162 kg (157.14 kg - 166.86 kg) CEM 152.5 R HES
    4 it can also be opted to add instead of a combination of two cement types (and this in all possible proportions), choosing either 100% CEM IIEA 42.5 N LA or 100% CEM I
    52.5 R HES • 30 kg (29.10 kg - 30.90 kg.) Fly ash • 697 kg (662.15 kg - 717.91 kg) of river sand 0/4 • 233 kg (226.01 kg - 239, 99 kg) limestone 2 / 6.3 • 934 kg (905.98 kg - 962.02 kg) limestone 6/20 • 169 liters (163.93 1 - 169 1) water (effective)
    Sieve residue concrete (lower limit): 0.063 100% 0.125 99% 0.25 97% 0.5 84% 1 74% 2 68% 4 57% 5.6 53% 6.3 50% 8 44% 10 35% 11.2 30% 12.5 25% 14 20% 16 12% 20 3% 22.4 1% 33.5 0% 40 0% 45 0%
    The raw materials were carefully weighed via suitable installations and mixed into a homogeneous concrete mix. The obtained spoil had the following specifications: • 2.384 kg (2.312.48 kg - 2.455.52 kg) volume mass • 0.52 (0.5 - 0.52) w / c - factor without absorption • 0.49 (0, 47 - 0.49) w / c factor with absorption • max. Alkali content 1.88 kg. • chloride content 0.14% compared to cement • 139 liters (401 kg) (134.83 l (388.97 kg) - 139 l (401 kg) of fine particles • theoretical volume 1,000 l (970 1. - 1.030 1.)
    Example 2
    To form a concrete floor that still needs to be polished, lm3 pumpable polished concrete was made. The requirements (BENOR) for the concrete were: strength class: C30 / 37; environment class: EE3; consistency class: S3. Additional requirement: pump concrete, polier concrete, min. Compressive strength on cube of 40 N / mm 2 instead of 37 N / mm 2, min. 350 kg cement, reinforced concrete.
    For this, the following raw materials in the quantities mentioned were used per cubic meter of concrete. Here, too, the lower limit and upper limit are always displayed within which the various raw materials can be added. In this example, no plasticizing auxiliaries (plasticizer or superplasticizer) were added.
    173 kg (167.81 kg - 178.19 kg) CEM III / A 42.5 N LA
    178 kg (172.66 kg - 183.34 kg) CEM 152.5 R HES
    4 it can also be opted instead of adding a combination of two cement types (and this in all possible proportions), choosing either 100% CEM 111 / A 42.5 N LA or 100% CEM I
    52.5 R HES • 0 kg fly ash • 718 kg (682.10 kg - 753.9 kg) river sand 0/4 • 231 kg (219.45 kg - 242.55 kg) limestone 2 / 6.3 • 923 kg (876.85 kg - 969.15 kg) limestone 6/20 • 169 liters (163.93 1 - 169 1) water (effective)
    Sieve residual concrete (lower limit): 0.063 100% 0.125 99% 0.25 97% 0.5 84% 1 73% 2 67% 4 56% 5.6 52% 6.3 49% 8 43% 10 35% 11.2 30% 12.5 25% 14 20% 16 12% 20 2% 22.4 0% 33.5 0% 40 0% 45 0%
    The raw materials were carefully weighed via suitable installations and mixed into a homogeneous concrete mix. The obtained spoil had the following specifications: • 2,393 kg (2,321.21 kg - 2,464.79 kg) volume mass • 0.48 (0.46 - 0.48) w / c - factor without absorption • 0.45 (0, 43 - 0.45) w / c factor with absorption • max. Alkali content 2.06 kg. • chloride content 0.13% compared to cement • 137 liters (404 kg) (132.871 (391.88 kg) - 137 1 (404 kg) of fine particles • theoretical volume of 1,000 liters (970 1. - 1.030 1.)
    Example 3
    To form a concrete floor that still needs to be polished, lm3 pumpable polished concrete was made. The requirements (BENOR) for the concrete were: strength class: C35 / 45; environment class: EE4; consistency class: S3. Additional requirement: pump concrete, polier concrete, min. Compressive strength on cube of 48 N / mm 2 instead of 45 N / mm 2, min. 380 kg cement, reinforced concrete.
    For this, the following raw materials in the quantities mentioned were used per cubic meter of concrete. Here, too, the lower limit and upper limit are always displayed within which the various raw materials can be added.
    188 kg (182.36 kg - 193.64 kg) CEM III / A 42.5 N LA
    193 kg (187.21 kg - 198.79 kg) CEM I 52.5 R HES
    4 it can also be opted instead of adding a combination of two cement types (and this in all possible proportions), choosing either 100% CEM III / A 42.5 N LA or 100% CEM I
    52.5 R HES • 0 kg fly ash • 708 kg (672.60 kg - 743.4 kg) river sand 0/4 • 227 kg (215.65 kg - 238.35 kg) limestone 2 / 6.3 • 910 kg (864.5 kg - 955.5 kg) limestone 6/20 • 169 liters (163.93 1 - 169 1) water (effective) • 1.2 kg superplast
    Sieve residual concrete (lower limit): 0.063 100% 0.125 99% 0.25 97% 0.5 84% 1 73% 2 67% 4 56% 5.6 52% 6.3 49% 8 43% 10 35% 11.2 30% 12.5 25% 14 20% 16 12% 20 2% 22.4 0% 33.5 0% 40 0% 45 0%
    The raw materials were carefully weighed via suitable installations and mixed into a homogeneous concrete mix. The obtained mortar had the following specifications: • 2,397 kg (2,325.09 kg - 2,468.91 kg) volume mass • 0.44 (0.42 - 0.44) w / c - factor without absorption • 0.41 (0, 39 - 0.41) w / c - factor with absorption • max. Alkali content 2.21 kg. • chloride content 0.13% compared to cement • 147 liters (433 kg) (142.59 1 (420.01 kg) - 147 1 (433 kg) fine particles • theoretical volume 1,000 liters (970 1. - 1.030 1.)
    If we now compare the concrete mortar according to the invention with the standard (BENOR) concrete mortar, we see a number of clear differences. 1) Lower water requirement + water to be added
    With each concrete composition, the w / c factor, both with and without absorption, is lower in the concrete mortar according to the invention than the usual standard BENOR concrete. This ensures a reduction in shrinkage and better durability of the concrete. Moreover, less water will evaporate at the concrete surface, so that the pore structure will be much denser here: (with current BENOR standardization value w / c factor without absorption) • 0.52 at C 25/30 EE2 according to the invention, while 0.55 at C standard C25 / 30 EE2 BENOR; 0.48 with C 30/37 EE3 according to the invention, while 0.50 with standard C30 / 37 EE3 BENOR; 0.44 with C 35/45 EE4 according to the invention, while 0.45 with standard C35 / 45 EE4 BENOR. 2) No or lesser (depending on concrete type) addition of plasticizer (s) PCE superplast in combination with a large volume of fine material ensures a viscous concrete mix. Water and unwanted air bubbles can therefore migrate more slowly to the concrete surface. This in combination with less free water (with standard concrete there is a greater water requirement of the raw materials) causes the concrete surface to dry out. Moreover, it is more likely that the bleeding water (due to its slower rise in the sticky concrete mass) and the air bubbles present are still rising while the surface is already being processed (compacted). Vibrations of the polishing machines ensure that these two elements are set in motion in the concrete mass. 3) Inert skeleton - grain distribution
    With the concrete mortar according to this invention, it runs much more constant compared to the standard BENOR concrete. This ensures a better cement matrix so that the concrete will be much more compact. This will directly result in less shrinkage and better durability. In addition, the less fine, the more limited the porous mortar layer on the surface. The shrinkage is important for both inside and outside floors, while the lower porosity is a positive additional characteristic for the frost / thaw sensitivity of the outside floors. 4) Chloride content
    This is significantly lower with the concrete mix according to the invention than with standard BENOR concrete. This reduces the chance of chloride-initiated corrosion of the reinforcement.
    5) ASR
    The maximum alkali content in the mortar according to the invention is lower than in standard BENOR concrete mortar. This therefore reduces the risk of ASR reaction between cement and granulates, making the concrete more durable.
    The floors (surface area between 1,200 and 1,800 m2) that were cast with the concrete mixtures described in examples 1 to 3 were polished. On the different molded floors, a panel of two poliers and a concrete expert visually determined that one month after completion of the works, no delamination had occurred over the entire surfaces. The surface itself was also much more durable than a concrete floor with sea sand. A thicker quartz wear layer was incorporated. During concreting, the concrete expert was also able to observe that the concrete was much leaner (less viscous) compared to a standard concrete. After concreting (and before polishing) the make-up water present came to the surface in a controlled manner to keep it moist, i.e. the concrete surface was sufficiently moist to allow the cement in the quartz to be hydrated. After checking the mixture of lists and the concrete, it turned out that 15 to 18 liters of water per m3 of concrete were dosed less than a standard polished concrete.
    Subsequent determinations were made by the same panel during a previously performed work where instead of river sand, finer sand was used. More specifically, a concrete floor of approximately 1,800 m2 was cast with the following concrete composition per m3: C25 / 30, 340 kg cement, S4, but with sea sand 0/4. According to the technical sheet, this sea sand had a fall of +/- 15 wt. % on the 250 μ sieve. These fine sands retain water in the mixture for much longer, resulting in delayed bleeding. After casting, the surface was sprinkled with quartz and provided with a curing compound. Damage phenomenon "delamination" occurred a few days after concrete pour. The abrasion resistance of the top layer was not optimal, because not enough quartz could be scattered. The top layer dried out faster than the under concrete, which meant that we had to start polishing prematurely, in order to still have enough moisture in the top layer to scatter the quartz and to achieve the flatness of the floor. During polishing it was observed by poliers that the under-concrete was not yet sufficiently cured. It was as if it were polishing on a "mattress". The vibrations of the machines drove the present fine matter of the concrete (unbound cement, fine sand, ...) upwards, together with the unbound water (around the sand grains) and this collected under the already partially incorporated quartz with a hollow sound as a result when the floor is tapped after finishing.
    As a result of concrete composition (excess of cement and fine sea sand, the water present in the concrete could not migrate up sufficiently quickly (to keep the top layer moist = bleeding), causing it to dry out (humidity). Also the effective water content was too low, since fine sand has a high water requirement.
    To maintain a certain fluidity (due to the concrete plant), the shortage of water was compensated by the addition of superplast. In this case, the addition of superplast in combination with fine sand resulted in a sticky concrete. Sticky concrete releases air and water more slowly because moisture transport in such concrete is very difficult.
    The above tests and findings clearly show that the use of coarser river sand with a particle size of less than 250 micrometers (µm) of a maximum of 6% by weight, instead of finer sands, will prevent the occurrence of delamination. The sand type (and its water requirement) in a mixture determines the dosage of cement (water / cement factor) and dosage of superplast (to compensate for shortage of water). These two actors do ultimately ensure the speed of binding and degree of hydration.
    权利要求:
    Claims (7)
    [1]
    CONCLUSIONS
    Castable concrete mortar suitable for forming a polishable concrete floor, comprising cement, sand, limestone and water, characterized in that said sand is river sand and that this river sand has a particle size of less than 250 micrometers (μηι) of a maximum of 6 wt. %.
    [2]
    Castable concrete mortar according to claim 1, characterized in that the concrete mortar contains at least 309 kg / m3 of cement.
    [3]
    Castable concrete mortar according to claim 1 or 2, characterized in that the water (w) / cement (c) factor without absorption of said concrete mortar is a maximum of 0.52.
    [4]
    Castable concrete mortar according to one of the preceding claims, characterized in that the concrete mortar contains at least 370 kg / m3 of cement.
    [5]
    Castable concrete mortar according to claim 4, characterized in that the water (w) / cement (c) factor without absorption of said concrete mortar is a maximum of 0.44.
    [6]
    Castable concrete mortar according to one of the preceding claims, characterized in that the concrete mortar contains at least 660 kg / m3 of river sand.
    [7]
    7. Method for manufacturing a pourable concrete mortar suitable for forming a polable concrete floor, characterized in that at least cement, water, limestone and river sand that have a particle size of less than 250 micrometres (pm) of a maximum of 6% by weight. are mixed into a homogeneous concrete mix.
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    同族专利:
    公开号 | 公开日
    BE1021820B1|2016-01-20|
    EP2905269A1|2015-08-12|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    DE2264075A1|1972-12-29|1974-07-18|Ardex Chemie Gmbh Chem Fab Wit|Mortar mix for plaster floors - giving pumpable consistency with water, contains portland cement and at least equal wt. of anhydrite or gypsum as binder for optimum shrinka|
    DE10159340A1|2000-12-05|2002-06-06|Akzo Nobel Nv|Lightweight, two-layer floor composition contains filler binder based on calcium sulfate, cement, magnesium oxide, mastic asphalt and/or bitumen and is reinforced with fibers, fabric or metal|
    EP1452503A1|2003-02-27|2004-09-01|Dyckerhoff Fertigbeton Saar GmbH &amp; Co. KG|Cement-bonded screed|
    DE202005020698U1|2005-01-08|2006-07-20|Henkel Kgaa|Dry mix useful for making fillers, floor finishes or floor-leveling screeds comprises Portland-limestone cement, aluminate cement and calcium sulfate in combination with iron sulfate and/or aluminum sulfate|
    DE202010014322U1|2009-02-06|2010-12-30|Unger, Alexander, Dr.|Thin floating screed|
    CN101786850A|2010-01-08|2010-07-28|北京天维宝辰化学产品有限公司|Modified cement-based self-leveling mortar and preparation method and application thereof|
    法律状态:
    2021-10-27| MM| Lapsed because of non-payment of the annual fee|Effective date: 20210228 |
    优先权:
    申请号 | 申请日 | 专利标题
    BE2014/0073A|BE1021820B1|2014-02-06|2014-02-06|PORTABLE CONCRETE FOR POLISHABLE CONCRETE FLOORS.|
    BE2014/0073|2014-02-06|
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