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BR-112021000278-B1 - Fireproof Compositions and Materials

BR112021000278B1BR 112021000278 B1BR112021000278 B1BR 112021000278B1BR-112021000278-B1

Abstract

The present invention relates to a composition in the form of a mixture comprising type F fly ash, a reactive silicon source, an adjustment accelerator and a lightweight aggregate with a density below 900 kg/m3 and a mechanical strength of at least 0.8 MPa, and the uses thereof for obtaining lightweight and fireproof building materials.

Inventors

  • SÁNCHEZ GRANADOS, LUIS
  • CRUZ YUSTA, MANUEL
  • BALBUENA JURADO, JOSÉ
  • FUERTES MARTÍNEZ, LUIS

Assignees

  • ADENIUM IBÉRICA, S.L

Dates

Publication Date
20260310
Application Date
20190711
Priority Date
20180711

Claims (20)

  1. 1. A composition in a dry mix form characterized in that it comprises: between 30 and 80% by weight of type F fly ash, between 1 and 9% by weight of a reactive silicon source, between 1 and 15% by weight of a setting accelerator, between 2 and 30% by weight of lightweight aggregates, wherein the % by weight is relative to the total weight of the composition in a dry mix form, wherein said composition is free of between 1.5% and 50% by weight of an alkaline agent, relative to the total weight of the composition in a dry mix form, and wherein said composition in a dry mix form has an apparent density, measured by the calibrated funnel method, between 200 and 600 kg/m3, preferably between 200 and 550 kg/m3, more preferably between 200 and 500 kg/m3.
  2. 2. Composition according to the preceding claim, characterized in that said composition has an apparent density between 400 and 900 kg/m3 when mixed with water at a liquid/solid weight ratio between 0.7 and 0.9, preferably between 450 and 850 kg/m3, more preferably between 500 and 800 kg/m3, measured in accordance with UNE EN 1015-6 before 5 minutes after mixing with water.
  3. 3. A composition according to any of the preceding claims, characterized in that said composition has a density between 200 and 600 kg/m3, preferably between 250 and 550 kg/m3, more preferably between 300 and 500 kg/m3, when mixed with water in a liquid/solid weight ratio between 0.7 and 0.9, test specimens of 4 x 4 x 16 cm are prepared and allowed to dry at room temperature for 28 days, in accordance with UNE-EN 1015-10.
  4. 4. Composition according to any of the preceding claims, characterized in that said composition comprises between 40% and 60% by weight, preferably comprising more than 40% by weight and less than 45%, of type F fly ash relative to the total weight of the composition in a dry mixture form.
  5. 5. A composition according to any of the preceding claims, characterized in that said composition comprises between 2% and 7%, preferably between 3% and 6% by weight of a reactive silicon source relative to the total weight of the composition in a dry mixture form; or wherein the reactive silicon source is a reactive silicon and aluminum source; or wherein the reactive silicon source is selected from metakaolin and an activated clay, preferably metakaolin.
  6. 6. Composition according to any of the preceding claims, characterized in that said composition comprises between 5% and 30% by weight of lightweight aggregates, preferably between 10% and 30% by weight of lightweight aggregates relative to the total weight of the composition in a dry mix form; or wherein the lightweight aggregate is selected from sand, gravel, arlite, perlite, vermiculite, and mixtures thereof, preferably selected from perlite and vermiculite, and mixtures thereof.
  7. 7. A composition according to any of the preceding claims, characterized in that said composition comprises between 3% and 12%, preferably between 4% and 9% by weight of a setting accelerator relative to the total weight of the composition in a dry mixture form; or wherein the setting accelerator is Ca(OH)2.
  8. 8. A composition according to any of the preceding claims, characterized in that the composition additionally comprises between 5% and 20% by weight, preferably between 5% and 18% by weight, of at least one solid cement, relative to the total weight of the composition in a dry mix form, preferably wherein the cement or cements are selected from Portland cement or gray cement, white cement, quick-drying cement, and mixtures thereof.
  9. 9. A composition according to any of the preceding claims, characterized in that it further comprises at least one solid additive selected from superplasticizers, accelerators, retarders, fluidizers, water retainers, aerators, and mixtures thereof; or in that it further comprises between 0.02% and 4.90% by weight, preferably between 0.02% and 2.00% by weight, more preferably between 0.02% and 1.00% by weight, even more preferably between 0.02% and 0.70% by weight, of at least one solid additive selected from superplasticizers, accelerators, retarders, fluidizers, water retainers, aerators, and mixtures thereof, with respect to the total weight of the composition in a dry mixture form.
  10. 10. A composition according to any of the preceding claims, characterized in that it additionally comprises at least one fiber; or in that it additionally comprises a fiber in a proportion of less than 1% by weight relative to the total weight of the composition in a dry mixture form; preferably in that the fiber is selected from fiberglass, glass wool, plastic fiber, or carbon fiber.
  11. 11. Composition according to any of the preceding claims, characterized in that the composition exhibits a mechanical compressive strength of at least 0.6 MPa, preferably between 0.6 and 1.4 MPa, more preferably between 0.7 and 1 MPa, when the composition is mixed with water in a liquid/solid weight ratio of 0.7 to 0.9, test specimens of 4 x 4 x 16 cm are prepared and allowed to dry at room temperature for 28 days, measured in accordance with UNE-EN 1015-11.
  12. 12. Composition according to any of the preceding claims, characterized in that said composition exhibits a fire resistance greater than 60 minutes when mixed with water in a liquid/solid ratio between 0.7 and 0.9, the mixture is mounted on a HEB 240 pillar protected on its four sides with a thickness of 13 mm, and allowed to dry at room temperature for 28 days, in accordance with UNE EN 13381-4 and UNE-EN 1363-1.
  13. 13. Composition according to any of the preceding claims, characterized in that it comprises: between 40 and 60% by weight of type F fly ash, between 2 and 7% by weight of a reactive silicon source, between 3 and 12% of a setting accelerator, between 5 and 30% by weight of lightweight aggregates, between 5 and 20% by weight of at least one cement, between 0.1 and 0.99% by weight of at least one fiber, between 0.02 and 1.00% by weight of at least one additive, with respect to the total weight of the composition in a dry mix form; or comprising: between 40 and 45% by weight of type F fly ash, between 3 and 6% by weight of a reactive silicon source, between 4 and 9% of a setting accelerator, between 10 and 30% by weight of lightweight aggregates, between 5 and 18% by weight of at least one cement, between 0.5 and 0.99% by weight of at least one fiber, between 0.02 and 0.70% by weight of at least one additive, relative to the total weight of the composition in a dry mix form; and water in a liquid/solid weight ratio between 0.5 and 0.95, preferably between 0.6 and 0.9, and more preferably between 0.7 and 0.9.
  14. 14. Process for preparing the composition as defined in any one of claims 1 to 13, characterized in that it comprises dry mixing the components.
  15. 15. Process according to claim 14, characterized in that it comprises dry mixing the components and subsequently mixing them with water.
  16. 16. Process according to claim 14, characterized in that it comprises designing the solid mixture obtained when dry mixing the components with the water stream, wherein the liquid/solid weight ratio is between 0.5 and 0.95, preferably between 0.6 and 0.9, and more preferably between 0.7 and 0.9.
  17. 17. Use of the composition as defined in any one of claims 1 to 13, characterized by being for coating surfaces, preferably for fireproofing surfaces.
  18. 18. Use according to claim 17, characterized in that the composition is applied by spraying.
  19. 19. Use according to claim 17, characterized in that the composition is applied in successive layers.
  20. 20. Use according to claim 17, characterized in that the final thickness of the composition is between 5 and 70 mm, preferably between 15 and 40 mm, more preferably between 20 and 30 mm, measured after drying for 28 days at room temperature in accordance with UNE EN 13381-4 standard.

Description

PRECEDENT TECHNIQUE [0001] Fireproof materials are highly desirable in the field of construction, due to the combustibility of the most commonly used building materials. Furthermore, it is desirable that said materials be lightweight to facilitate handling and application. [0002] US2012172469 A1 describes lightweight cement compositions based on fly ash with an alkali metal salt of citric acid intended for obtaining lightweight compositions with high compressive strength and water resistance that set quickly, without seeking fire resistance. [0003] CN106927735A describes a mortar containing fly ash, rice husks and silica fume, and its use as a thermal insulator for wall coverings. [0004] WO2008157714 A1 describes compositions comprising cenospheres, a silicate base, and an organosilane compound, obtained in aqueous solution for obtaining fire-resistant materials. [0005] WO2011104007 A2 describes an aqueous composition with cenospheres, ceramic fibers, colloidal silica, and other components for its use in fire protection of walls and ceilings. [0006] There is a need to find fireproof materials with high fire resistance that are also low density and environmentally friendly. DESCRIPTION OF THE INVENTION [0007] The compositions of the present invention are excellent for preparing fireproof materials, particularly as they have excellent fire resistance properties and their density is low enough to allow their use in walls and ceilings. In addition, these compositions can be used to prepare lightweight fireproof panels that are easy to transport and install, and have excellent fireproof properties. [0008] A highly advantageous aspect of the present invention is that it uses waste materials, such as fly ash, as the main component, which makes the fireproof product very environmentally friendly given its low carbon footprint. Another advantage of the present invention is that once exposed to fire, the fireproof material becomes even more fire-resistant. [0009] The fact that the compositions of the present invention are dry mixtures is extremely convenient for their stability during storage and transport, as well as for the ease of their end use. [0010] In addition, the compositions of the present invention settle at room temperature, so they do not require a temperature treatment which, in wall and ceiling spraying applications, would be complex and costly. [0011] The inventors of the present invention have found that mixed compositions as defined in the claims are particularly advantageous for projection onto walls and ceilings, since they have excellent adhesion, can set at room temperature, achieve optimal mechanical strength and, in particular, exhibit unexpected fire-resistant properties. Similarly, the inventors have found that the compositions of the present invention can be used to form panels in molds that also exhibit mechanical strength, allowing their removal from the mold, storage, and transport to their final use location, and, in particular, have fire-resistant properties that are highly convenient for the construction field. [0012] In a first aspect, the present invention relates to a composition in the form of a dry mixture comprising: [0013] between 30 and 80% by weight of type F fly ash, [0014] between 0 and 30% by weight of a reactive silicon source, [0015] at least 1.5% by weight of a solid alkaline agent, [0016] at least 0.5 and 10% of a starting accelerator, and [0017] between 2 and 15% by weight of a lightweight aggregate, [0018] where % by weight is relative to the total weight of the composition in a dry mix form, [0019] The aforementioned composition has a density below 900 kg/m3 when mixed with water at a liquid/solid weight ratio of 0.5, test specimens of 4 x 4 x 16 cm are prepared and allowed to dry at room temperature for 28 days, measured as per UNE-EN 1015-10, [0020] where said composition has a mechanical compressive strength of at least 0.8 MPa when mixed with water at a liquid/solid weight ratio of 0.5, test specimens of 4 x 4 x 16 cm are prepared and allowed to dry at room temperature for 28 days, measured as per UNE-EN 1015-11, [0021] The layer weight is an average value obtained from several measurements using a thickness measuring device installed and measured as per UNE EN-13381-4. [0022] Fly ash is the finest particles generated in the combustion of coal (pulverized anthracite or other bituminous coals) in thermal power plants. Fly ash is defined by the UNE-EN 450-1:2006 + A1:2008 standard as “a fine powder with mainly spherical crystalline particles, produced by the combustion of pulverized coal with or without co-combustion materials, with pozzolanic properties and mainly composed of SiO2 and Al2O3; the reactive SiO2 content defined in the EN 197-1 standard is at least 25% by mass.” According to ASTM C Standard 618-08a, fly ash is classified by lime content as type or class F when it is produced by calcination of anthracite or bituminous coal and contains amounts of lime