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GB2266886A - Lightweight concrete compositions - Google Patents

Lightweight concrete compositions Download PDF

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Publication number
GB2266886A
GB2266886A GB9210376A GB9210376A GB2266886A GB 2266886 A GB2266886 A GB 2266886A GB 9210376 A GB9210376 A GB 9210376A GB 9210376 A GB9210376 A GB 9210376A GB 2266886 A GB2266886 A GB 2266886A
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GB
United Kingdom
Prior art keywords
compositions
incorporation
casting
aggregate
mica
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB9210376A
Other versions
GB9210376D0 (en
GB2266886B (en
Inventor
Royston Edgar Dennis Fox
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to GB9210376A priority Critical patent/GB2266886B/en
Publication of GB9210376D0 publication Critical patent/GB9210376D0/en
Publication of GB2266886A publication Critical patent/GB2266886A/en
Application granted granted Critical
Publication of GB2266886B publication Critical patent/GB2266886B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02Granular materials, e.g. microballoons
    • C04B14/04Silica-rich materials; Silicates
    • C04B14/20Mica; Vermiculite
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04HBUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H17/00Fencing, e.g. fences, enclosures, corrals
    • E04H17/14Fences constructed of rigid elements, e.g. with additional wire fillings or with posts
    • E04H17/20Posts therefor
    • E04H17/21Posts therefor with hollow cross sections
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02Granular materials, e.g. microballoons
    • C04B14/04Silica-rich materials; Silicates
    • C04B14/20Mica; Vermiculite
    • C04B14/204Mica; Vermiculite expanded
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions 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
    • C04B28/04Portland cements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04HBUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H12/00Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
    • E04H12/22Sockets or holders for poles or posts
    • E04H12/2253Mounting poles or posts to the holder

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

Cement based casting compositions are formulated in which the sand and aggregate in conventional concrete are replaced by a low density mineral of particle size suitable for its intended use, together with other additives to ensure that the finished castings possess adequate flexural strength. The light weight and high thermal insulation of such castings can be further enhanced by design features to facilitate handling and the use of a suitable primer, with or without a pigmented top coat, to protect the castings from the destructive effects of weathering, as well as to provide a pleasing appearance. Exfoliated mica (vermiculite) is the low density mineral used, optionally together with calcined mica. The compositions are used to make e.g. building components, fencing posts and gravel boards.

Description

The Formulation of Lightweight Concrete Compositions and their use for Items such as Pre-Cast Buildinq Components, Fencing Posts, Gravel Boards, and other Items where Light Weight and/or High Thermal Insulation is of Benefit This invention relates to concrete compositions of light weight and high thermal insulation characteristics, and their use for the casting of items where either or both of these properties are of benefit, such as pre-cast building components for such as garages, or gravel boards and posts for fencing, with particular reference to the latter. The weight reduction can be further enhanced by features of design in most,if not all,cases.
The design features are such that they can lead to other design improvements such as an improved method of installation which would not otherwise be practicable, but which will be possible for one person without the need for special equipment or mechanical aids. Also further enhancements by the use of coatinys which will not only improve their appearance,but will also protect the concrete and steel reinforcement from the destructive effects of weathering, such as cracking arising from the corrosion of the steel and freeze/thaw cycles.
Concrete Fencing Posts and Gravel Boards are superior to their timber counterparts since they are not subject to wet rot at ground level as are the latter.
However they suffer the serious disadvantage of a much greater weight so that for the longer posts particularly, it is really necessary to employ lifting tackle if they are to be installed successfully. Thus it is most often the case that a specialist contractor has to be engaged to supply and install.
Thus if the installation of such fencing is to come truly within the domain of 'Do-It-Yourself' significant W ht reductions of the concrete items are essential. Also the high weight factcr leads to high transport cost with the result that manufacture and supply is not viable on a national basis, it therefore tends to be carried out on a local basis only.
A further disadvantage lies in the need to use steel reinforcement in order to compensate for the poor mechanical strength of the concrete in tension.
The penetration of water into the concrete when it is in exposed locations causes rusting and the consequent expansion of the steel leads to stress cracking within the concrete. This in turn leads to increased water penetration and the cycle is repeated. Add to these effects those resulting from a series of freeze/thaw cycles and it is only a matter of- time before disinte- gration of the concrete is sufficient to render it unfit for its purpose.
Finally some regard the appearance of both new and weathered concrete.as aesthetically displeasing compared with that of timber, and would prefer to be able to obtain it in what they would regard as appropriate colours and appearance.
According to the present invention weight reductions of up to 80 ó are attainable by various means. Partly by replacement of conventional aggregate chips with a light weight siliceous mineral aggregate. Partly by the substitution of calcined mica for all or part of the silica sand content of a conventional concrete, or by a combination of these means together with the provision in the design of the casting for one or more hollow cores as appropriate. In the case of posts this also provides the means for accomodating a suitably designed mounting unit, which will not only permit the satisfactory installation of the posts by one person, but will also permit their easy removal should that become necessary or desirable.Some loss of mechanical strength can be recovered by the incorporation of a proportion of polymer emulsion in the concrete formulation, as well as by increasing the cement content.
Decoration and protection of the concrete as cast is achieved firstly by treatment with a primer based upon a soluble metal silicate, in which is incorporated a silicone emulsion to provide water repellancy. This is followed by the use of a suitably pigmented top coat which is similarly based. This treatment will also serve to reinforce the surface of the casting.
Specific embodiments of the invention will now be described with reference to the following formulation examples and the accompanying drawings: Example 1 Example 2 Portland Cement 2.0 pts. vol. Portland Cement 2.0 pts. vol.
Silica Sand 5.0 " " Vermiculite 4mm. 10.0 " Vermiculite 2-4mm. 8.0 " tt Water 2.6 " Water 2.6 " Example 3 Example 4 Portland Cement 2.0 pts. vol. Portland Cement 2.0 pts. vol.
Calcined mica 5.0 " " Calcined mica 1.0 Vermiculite 2-4mm. 4.0 " " Vermiculite 16mm. 6.0 Water 2.6 " " Water 2.6 " Plasticiser 0.1 Example 5 Example 6 Portland Cement 2.0 pts. vol. Cement Blend* 2.0 pts. vol.
Calcined mica 1.0 " " Calcined mica 1.0 " Vermiculite 16mm. 6.0 " " Vermiculite 16mm. 6.0 " Polyvinyl Acetate Polyvinyl Acetate Emulsion 50X 0.2 " " Emulsion 50 Ó 0.2 Water 2.4 " " Water 2.4 " * Cement Blend = 65 Portland + 35'1Ó High Alumina Cements.
Example 7 Example 8 Cement Blend* 2.0 pts. vol. Cement Blend* 2.0 pts. vol.
Calcined mica 1.0 " " Calcined mica ' 1.0 " Vermiculite 16mm. 6.0 " " Vermiculite 16mm. 6.0 " Acrylic Emulsion 50'l0 0.2 " " Acrylic Emulsion 505 0.2 " Water 2.4 " " Accelerator# 0.02 " Water 2.6 " Accelerator = Calcium. Formate Fig 1 shows a broken view of the slotted side elevation of a fencing post in which 1 is the upper section of the post, 2 is the side slot, 3 is the hollow core and 4 is the lower section.
Fig 2 is a plan view of the post at its base in which at 5 are the steel reinforcing rods, 6 is the base of the hollow core and 7 is the top. At 2 are the slots.
The mounting unit shown in Figs 7 and 8 consists essentially of a longitudinally split tube of appropriate length shown at Fig 6, which is assembled with the foot assembly shown in Fig 5. The foot assembly consists of two components shown in Figs 3 and 4, the former having a slot in the centre from its base up to the halfway point while the latter has a similar slot except that it can be seen to run from the halfway point to the top. In fact of course they are identical That in Fig 4 is simply that in Fig 3 inverted prior to assembly to form that shown in Fig 5. The tube in Fig 6 has an outside diameter similar to the inside diameter of the hollow core of the post, at the base,or point of entry.The slight taper of the core, which is provided so that the mandrel used to form it during casting may be withdrawn, will have the effect of compressing the split in the mounting tube as it is inserted, so that it will conform to the very slightly reducing core diameter and thus ensure a snug tight fit. At the lower end the mounting tube at Fig 6 carries three further slots at 900 intervals, the function of which, with the original split or slot is to accomodate the 'foot assembly or anchorage' of the mounting unit as shown in Fig 7 and Fig 8. The width dimension of all slots, other than that formed by the split in the tube, will match the gauge of the sheet steel used. The width dimension of the longitudinal split needs to be sufficient to accomodate its compression by the taper of the core,as well as being sufficient to accomodate the gauge of the steel employed. The mounting unit thus formed is inserted into a previously dug hole, using suitable means to ensure its verticality,such as the insertion of a pole,of appropriate diameter bearing a plumb line, into the mounting tube. Freshly mixed concrete is then poured to a suitable depth to anchor the unit in position. When it has set hard the post can be fitted to the mounting unit and the hole filled in. The installation will then appear as shown in Fig 7.
All metal will be zinc galvanised to protect against corrosion.

Claims (12)

CLAIMS What I claim is:
1. The use of exfoliated mica, otherwise known as vermiculite, as a blend of various particle sizes,in a cement based casting composition, to replace the gravel or limestone chippings normally found in most concrete casting compositions, in order to reduce the weight of the finished casting.
2. The further use of exfoliated mica as in Claim 1. to replace the sand as well as the aggregate in the composition and thereby achieve a further weight reduction.
3. The incorporation of a proportion of calcined mica into compositions as in
1. and 2. to improve the flexural strength of the composition, albeit at the cost of some weight reduction.
4. The incorporation of a proportion of a polymer emulsion into compositions as in Claims 1. to 3. to improve flexural strength.
5. The use of blends of Portland and High Alumina cements to improve setting times of compositions as in claims 1. to 4.
6. The use of a finely ground grade of cement in compositions as in claims 1.
to 4. to improve the setting times and penetration of the cement particles into pores present in the aggregate.
7. The incorporation of a plasticiser into compositions as in claims 1. to 6.
to further enhance penetration of and bonding to the aggregate.
8. The incorporation of an accelerator into compositions as in claims 1.to 7.
to further enhance setting times.
9. The incorporation of hollow cores as a design feature of castings prepared from compositions as in Claims l.to 7., to reduce casting weight and at the same time provide a receptacle for a suitable mounting device where appro priate.
10. The provision of a simple mounting device to exploit the design feature as described in Claim 9.
11. The use of a suitable primer on castings prepared from compositions as in Claims 1.to 7.,based upon a soluble metal silicate with a water repellent such as a silicone emulsion, to prevent the ingress of water into the casting and to consolidate and strengthen its surface matrix where desired.
12. The use of a pigmented version of the primer as in Claim 10. to provide a decorative finish and further enhance the protection afforded by the primer.
GB9210376A 1992-05-14 1992-05-14 Concrete compositions for items such as pre-cast building components, fencing posts and gravel boards requiring light weight and/or high thermal insulation Expired - Fee Related GB2266886B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9210376A GB2266886B (en) 1992-05-14 1992-05-14 Concrete compositions for items such as pre-cast building components, fencing posts and gravel boards requiring light weight and/or high thermal insulation

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9210376A GB2266886B (en) 1992-05-14 1992-05-14 Concrete compositions for items such as pre-cast building components, fencing posts and gravel boards requiring light weight and/or high thermal insulation

Publications (3)

Publication Number Publication Date
GB9210376D0 GB9210376D0 (en) 1992-07-01
GB2266886A true GB2266886A (en) 1993-11-17
GB2266886B GB2266886B (en) 1995-11-15

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GB9210376A Expired - Fee Related GB2266886B (en) 1992-05-14 1992-05-14 Concrete compositions for items such as pre-cast building components, fencing posts and gravel boards requiring light weight and/or high thermal insulation

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2277763A1 (en) * 2005-10-19 2007-07-16 Javier Porcar Orti Micem-Megafino heat and sound insulation mica and white cement based mix comprises a blend with water and additives, forming a stucco effect product
RU2312839C1 (en) * 2006-04-04 2007-12-20 Закрытое акционерное общество "Дигаз" Raw mixture for manufacturing building material and article
RU2473517C1 (en) * 2011-08-17 2013-01-27 Федеральное Государственное Автономное Образовательное Учреждение Высшего Профессионального Образования "Сибирский Федеральный Университет" Crude mixture for making light concrete
RU2473518C1 (en) * 2011-08-17 2013-01-27 Федеральное Государственное Автономное Образовательное Учреждение Высшего Профессионального Образования "Сибирский Федеральный Университет" Crude mixture for making light concrete articles
GB2493221A (en) * 2011-10-12 2013-01-30 Royston Edgar Dennis Fox Building components having plastic reinforcing rods

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB498050A (en) * 1937-07-14 1939-01-03 Evelyn Hurden Improvements in or relating to walls and fences
GB573069A (en) * 1943-10-28 1945-11-05 William Henry Glaysher Improvements relating to supports for fences and the like structures
GB623660A (en) * 1946-07-11 1949-05-20 Vilas Eugene Watts Improved light-weight aggregate and method of producing the same
GB790636A (en) * 1955-01-14 1958-02-12 Samuel Clipson Improvements in and relating to exfoliated vermiculite
GB1068782A (en) * 1965-01-01 1967-05-17 Edgar Gregson Improvements in building bricks
GB2072156A (en) * 1978-09-18 1981-09-30 Tile Pty Ltd U Novel slab, manufacture and applications thereof
EP0065410A1 (en) * 1981-05-12 1982-11-24 The British Petroleum Company p.l.c. Thermally insulating filler and compositions containing such a filler
EP0219579A1 (en) * 1985-09-16 1987-04-29 Dave D. Barrett, Jr. Insulating cementitious mixture and method of use

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB498050A (en) * 1937-07-14 1939-01-03 Evelyn Hurden Improvements in or relating to walls and fences
GB573069A (en) * 1943-10-28 1945-11-05 William Henry Glaysher Improvements relating to supports for fences and the like structures
GB623660A (en) * 1946-07-11 1949-05-20 Vilas Eugene Watts Improved light-weight aggregate and method of producing the same
GB790636A (en) * 1955-01-14 1958-02-12 Samuel Clipson Improvements in and relating to exfoliated vermiculite
GB1068782A (en) * 1965-01-01 1967-05-17 Edgar Gregson Improvements in building bricks
GB2072156A (en) * 1978-09-18 1981-09-30 Tile Pty Ltd U Novel slab, manufacture and applications thereof
EP0065410A1 (en) * 1981-05-12 1982-11-24 The British Petroleum Company p.l.c. Thermally insulating filler and compositions containing such a filler
EP0219579A1 (en) * 1985-09-16 1987-04-29 Dave D. Barrett, Jr. Insulating cementitious mixture and method of use

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2277763A1 (en) * 2005-10-19 2007-07-16 Javier Porcar Orti Micem-Megafino heat and sound insulation mica and white cement based mix comprises a blend with water and additives, forming a stucco effect product
ES2277763B1 (en) * 2005-10-19 2008-06-01 Javier Porcar Orti MICEM-MEGAFINO, COMPOSITE OF MICA AND WHITE CEMENT, FOR THE STUDY OF SURFACES AS THERMAL AND ACOUSTIC INSULATION.
RU2312839C1 (en) * 2006-04-04 2007-12-20 Закрытое акционерное общество "Дигаз" Raw mixture for manufacturing building material and article
WO2007114738A3 (en) * 2006-04-04 2007-12-21 Zakrytoye Aktsionernoye Obsche Raw mix for producing constructional materials and articles
GB2449407A (en) * 2006-04-04 2008-11-19 Zakrytoye Aktsionernoye Obsche Raw mix for producing constructional materials and articles
GB2449407B (en) * 2006-04-04 2011-06-01 Zakrytoye Aktsionernoye Obschestvo Digaz Crude Mixture used to fabricate Construction Materials and Products
RU2473517C1 (en) * 2011-08-17 2013-01-27 Федеральное Государственное Автономное Образовательное Учреждение Высшего Профессионального Образования "Сибирский Федеральный Университет" Crude mixture for making light concrete
RU2473518C1 (en) * 2011-08-17 2013-01-27 Федеральное Государственное Автономное Образовательное Учреждение Высшего Профессионального Образования "Сибирский Федеральный Университет" Crude mixture for making light concrete articles
GB2493221A (en) * 2011-10-12 2013-01-30 Royston Edgar Dennis Fox Building components having plastic reinforcing rods

Also Published As

Publication number Publication date
GB9210376D0 (en) 1992-07-01
GB2266886B (en) 1995-11-15

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 20100514