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WO2003035571A1 - Compositions d'isolants non inflammables, thermiques et phoniques, elements de construction realises a partir de ces dernieres et procedes de production associes - Google Patents

Compositions d'isolants non inflammables, thermiques et phoniques, elements de construction realises a partir de ces dernieres et procedes de production associes Download PDF

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Publication number
WO2003035571A1
WO2003035571A1 PCT/IB2002/004433 IB0204433W WO03035571A1 WO 2003035571 A1 WO2003035571 A1 WO 2003035571A1 IB 0204433 W IB0204433 W IB 0204433W WO 03035571 A1 WO03035571 A1 WO 03035571A1
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WO
WIPO (PCT)
Prior art keywords
rubber material
composition according
mixture
particulate rubber
sand
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.)
Ceased
Application number
PCT/IB2002/004433
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English (en)
Inventor
Yvan Werner
Pierre Noel Ventalon
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Individual
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Individual
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Filing date
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Publication of WO2003035571A1 publication Critical patent/WO2003035571A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/20—Waste materials; Refuse organic from macromolecular compounds
    • C04B18/22—Rubber, e.g. ground waste tires
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/52—Sound-insulating materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to the field of building techniques, and in particular to building materials, and more specifically compositions that are used as building elements' or can be used to make building elements.
  • the invention is more particlularly concerned with compositions that have improved phonic, and thermal properties, that are intended to be incorporated or used in the primary or secondary structure of a building, and may therefore also include prefabricated building elements that are made up of the compositions of the invention.
  • concrete One well known example of a building material is concrete.
  • a material before curing or setting, generally comprises cement, sand and water. It is known to add various additives to improve the properties of the concrete, or to lend the properties of these additives to the concrete. Once set or cured, the concrete has a given set of thermal and phonic capabilities that are generally rather limited and do not enable satisfactory dampening of sound transmission.
  • the composition contains portland cement, powdered rubber and a polymer emulsion.
  • NL 69 02 138 describes a screeding composition containing portland cement, an acrylic-styrene resin suspension, rubber flour, rubber granules and rubber fibres.
  • FR E 50 140 discloses the use of styrene-butadiene suspensions in cement compositions also comprising rubber, for the manufacture of screeding.
  • compositions for a phonically insulating screeding to be placed beneath tiling contains a mixture of an emulsion of carboxylated polymer with a solid component containing cement and rubber grains and fibres.
  • particulate rubber material has a particle size comprised between about 2 mm to about 7 mm and is present in a proportion of between about 20% to about 80% by volume with respect to the total volume of the dry mixture.
  • Surface smoothing agents are substances that are designed to smooth the outer surface of the structures that are made with hydraulic binding agents, e.g. screed floorings.
  • a commonly used surface smoothing agent is anhydrous calcium sulfate. Where a surface smoothing agent is used in the compositions of the present invention, this is therefore preferably anhydrous calcium sulfate, but other agents known to the skilled person may be used instead.
  • a composition according to the invention incorporating such a smoothing agent has faster drying characteristics, and improved water infiltration resistance, and can therefore be used in buildings where water infiltration can be a problem, or in bathrooms, water closets, showers and the like.
  • building element precast, cast or otherwise formed structures, that form part of, or are used to create a building.
  • Such elements are well known in the art and comprise, breeze blocks, pillars or columns, generally non-load bearing cast walls or partitions, cast floors, screeds, drawn floors, and filler walls, e.g. walls that are created by pouring concrete between two pre-existing load bearing walls, ceilings and the like.
  • hydroaulic binding agent it is meant a generally powdered or particulate natural or synthetic mineral compound or composition that when mixed with water will set hard to form a solid material.
  • Suitable “hydraulic binding agents” are various types of cements, e.g portland cement, CPA portland cement, CPJ portland cement, plaster, gypsum, aluminosilicates, and the like that are well known as such to the skilled person and commonly available.
  • particulate rubber material rubber particles that are obtained from shredding, tearing or grinding of rubber, for example, waste rubber originating from cut offs from the manufacture of drive or conveyor belts, or for example rubber originating from used tyre recovery and recycling.
  • the size of the rubber particles has advantageously been determined by the present inventors as being comprised from about 2 mm to about
  • compositions of the present invention it has been possible to incorporate particulate rubber material as defined above in quantities that were never thought possible before while maintaining the resistance to inflammation.
  • an average granulometry of about 4 mm for the particulate rubber material is preferred.
  • a granulometry of between about 3 mm to about 7 mm is preferred, and most preferably one can use an average granulometry of 5 mm.
  • the term "average" refers to the median of a distribution of particles of particulate rubber material.
  • the shredding, tearing or grindin process of the particulate rubber material has an impact on the compositions of the present invention, and preferably the rubber particles advantageously have a completely irregular shape. Rubber particles prepared in this way have the required elasticity and surface roughness enabling them to be incorporated into the cement and water mix and to produce the flame resistant, thermal and phonic insulating compositions according to the invention.
  • the particulate rubber material is used in a quantity corresponding to about 20% to about 60% of the total volume of dry components, which represents about 10% to about 30% by weight with respect to the total weight of the mixture.
  • the ratio of cement to water in the compositions of the present invention is about 0.75:1
  • traditional concrete compositions have a ratio of cement to water of about 0.5:1. It will therefore be appreciated that the compositions of the present invention have far less water than those of traditional concrete compositions, whilst still maintaining inflammability, mechanical properties, and advantageous thermal and phonic insulating properties.
  • compositions of the present invention since it makes them too liquid to be able to work with, causes loss of integration of the particulate rubber material and of course leads to much longer curing times, the latter being especially redhibitory for its economic impact on construction and manufacturing turn around times.
  • too much water is deleterious to the compositions of the present invention, because it washes the particulate rubber material and reduces the adhesion of the hydraulic binding agent to the former. This is one of the problems that occurs with compositions such as that proposed in German DE 2 213 034, which have a very high water content.
  • the water content is preferably only from about 7 to about 12% water by total weight of the other dry components.
  • the hygrometry that is to say, the percentage of water vapour present in the element as measured by an electric current sent across the element between two electrodes, of precast building elements made from compositions according to the invention will be about 5% humidity, whereas for building elements that are demolded after curing for, say 12 to 48 hours, it will preferably be about 7 to 12%.
  • Another object of the present invention is a concrete, having improved flame resistance, phonic and thermal absorption or insulation properties, that can be used to manufacture building elements or components that are not load bearing in buildings, for example by pouring the concrete in situ into preplaced and prefixed building moulds, or by pouring it into moulds of a suitable size and shape for making prefabricated, non-load bearing building elements.
  • another object of the invention is to make prefabricated building elements, but this should not exclude from view the possibility of producing other forms of elements and other modes of use or application of the compositions according to the present invention.
  • non load-bearing building elements include, but are not limited to, horizontal or vertical building elements, such as outer non load-bearing walls, partitions, flooring blocks, and breeze blocks.
  • the invention will also find application in building elements that are not strictly speaking structural building elements, such as cladding panels, curtain walls and alabaster type or cement based wall coverings.
  • the cement and particulate rubber material are components that are generally provided in packets or sachets, whereas the sand will be generally available quarry or dredging sand, or whatever form of sand may be available at the building site or in the neighborhood.
  • the sand is a sand obtained by crushing or grinding porous volcanic rock, e.g. pouzzolane, or pumice. The use of such types of sand lowers the mass of the overall composition and any building elements made therefrom, making them easier and cheaper to manipulate, store and transport.
  • a mixture of CPA or CPJ cement and particulate rubber material ready for use for the manufacture of concrete, comprising a proportion of particulate rubber material between about 20% to 80% with respect to the total volume of the mixture.
  • the particulate rubber material is obtained by grinding or shredding rubber that has advantageously been recovered from used tyres, and even more preferably, such particulate rubber will have undergone, at least in part, an expansion step.
  • the optional, yet advantageous expansion step involves either hammering the particulate rubber material, for example in a hammer and anvil apparatus, or crushing the particulate rubber material in between rollers.
  • the particulate rubber material passes through the hammer/anvil apparatus or the rollers before being packaged into sachets, bags or sacks.
  • This optional step surprisingly creates one or more cavities within the center of the particulate rubber material, but also lacerates the outer surface of the particles, which consequently become porous. From then on, the air trapped in the central cavities seems to increase the phonic and thermal insulating properties of the particulate rubber material, whereas the porous surface increases adhesion to the mixture of sand and cement. On the whole, the general phonic and thermal insulating properties of the particulate material are noticeably increased with respect to untreated particulate rubber material.
  • the present inventors suppose that the increase in favourable properties is due to an electrostatic effect, and in particular, an electrification or electrostatic polarisation of the particles during the expansion step, that is maintained when the particulate material is mixed with the mixture of cement, sand and water.
  • a method for manufacture of the compositions according to the invention comprising:
  • the particulate rubber material has a particle size comprised between about 2 mm to about 7 mm and is present in a proportion of between about 20% to about 80% with respect to the total volume of the mixture.
  • a method is applicable both on a small scale, for example for a domestic user or workman wishing to make up a small amount of composition according to the invention, as well as on an industrial, using precast building element apparatus well known to the skilled person, e.g. using vibration molds, immediately followed by a demolding step. In such a case, it is most preferred to use quantities of particulate rubber material in the range from about 23% to about 25% of the total volume of dry mixture.
  • particulate rubber material where the building elements are only demolded after curing, e.g. for between 12 and 48 hours, it is preferred to use higer quantities of particulate rubber material, and most preferably quantities of particulate rubber material representing 60% of the total volume.
  • higer quantities of particulate rubber material and most preferably quantities of particulate rubber material representing 60% of the total volume.
  • An example of a preferred formulation used on an industrial scale is the following: -90 kg particulate rubber material, average granulometry 4 mm
  • the total volume of the mixture is about 800 litres, wherein 90 kg of particulate rubber material represents about 180 I i.e. 1/5 of the total volume of the mixture and therefore 20% of the volume.
  • - Figure 1 is a schematic representation of a particulate rubber material obtained from grinding industrial rubber prior to treatment
  • - Figure 2 is a similar schematic representation of a particulate rubber material originating from ground rubber from a used tyre before treatment ;
  • FIG. 3 is a schematic illustration of a particle of Figure 2 after the expansion step treatment ;
  • FIG. 4 is a section view of the treated particle of Figure 3 ;
  • - Figure 5 is a schematic side-view representation of a hammer and anvil apparatus used in the expansion step for treating the untreated rubber to provide the particulate rubber material used in the compositions of the present invention ;
  • - Figure 6 is a schematic side-view representation of a crushing roller apparatus used in the expansion step for treating the untreated rubber to provide the particulate rubber material used in the compositions of the present invention
  • - Figure 7 is a schematic side-view representation of a prefabricated slab made with a concrete composition according to the present invention, the shape of which has been optimized to give the best performance ;
  • - Figure 8 is a chart of the phonic insulating properties taken from Table II.
  • compositions falling within the scope of the present invention that provide the desired phonic and thermal insulation properties of a building element product based on those compositions.
  • Table II shows the results of testing the compositions of the invention as indicated above for the phonic insulation capabilities, using the percentage of sound transmitted through samples of precast and set building elements that were 6cm thick, in accordance with the French and European standards NF EN ISO 140-3 and 140-6. TABLE II
  • the mixture of particulate rubber material at 40% by. volume corresponds to the mixture II of table I
  • the mixture of particulate material at 80% by volume corresponds to mixture V of table I. It is evident from these tests that a composite material made from the compositions of the present invention has far better phonic absorption or insulation capabilities than rockwool.
  • Figure 1 shows a particle of untreated particulate rubber material, when viewed under a microscope with 20x enlargement.
  • the particle is obtained from the grinding or shredding of industrial rubber, for example from waste or cut-offs from conveyor belt manufacture.
  • the structure is smooth, compact and homogenous, even though the particle has a generally angular relief.
  • Figure 3 shows a particle of particulate rubber material according to the invention that has been expanded by hammer and anvil treatment.
  • the particle has a much higher volume, its surface appears more fibrous, and the particle has become softer to the touch.
  • a hammer and anvil apparatus is shown schematically in a side-view, where the anvil 5 is sloping and one or more hammers 6 are arranged along the slope.
  • the untreated particles are poured down the slope from a hopper 7, and as they fall down, are hammered by the falling movement of the hammers against the slope of the anvil.
  • the particles exit the apparatus at the bottom of the slope and are collected on a belt that takes them on to a bagging unit.
  • a crushing roller unit is shown schematically from the side.
  • the apparatus comprises a series of paired 11 parallel rollers 12, separated only by a very short distance, for example, between 1/10 and 5/10 of a millimeter.
  • the apparatus comprises three pairs of rollers, superposed in a vertical channel 13.
  • a slab comprising pretensioned struts 15 or girders and ribbed Hourdis stones or bricks 16.
  • the bricks are made from compositions according to the present invention and fit ideally into the gaps between the pretensioned struts 15 with slight compression, such that the ribbed ears or extended shoulders 17 slot in and around the I shaped struts.
  • This construction is a very efficient fire barrier, since the prefabricated Hourdis bricks made with compositions of the present invention are also fire resistant.
  • the lower surface 18 of the extended shoulder 17 enables other components to be affixed underneath, by screwing, such as a false ceiling, whereas the vaulted space remaining 19 enables the run through of cabling and electrical wiring, heating and air conditioning ducts and the like.
  • This extra space also offers complementary sound absorption in addition to that provided by the compositions of the present invention.
  • compositions according to the present invention have exceedingly good resistance to fire.
  • M1 and M2 classification of inflammable materials the compositions of the present invention were capable of obtaining these classifications.
  • a first composition according to the invention was prepared with the following :
  • 18 kg of particulate rubber represents about 36 I, i.e. 20% of the total volume of the mixture.
  • a second composition was according to the invention was prepared with the following :
  • Example 3 M1 and M2 flame resistance test
  • the tests M1 and M2 are standard tests corresponding to French norm NF-P-92- 501.
  • M1 and M2 flame resistance test standard a 30x40 cm sample of the concrete is angled at 45° to a radiating electrical heat source placed at 3 mm from the sample. The gases that evolve during heating passed over igniters that are arranged around the sample. The test lasts 20 minutes.
  • the criteria retained for assessing flame resistance are : initial time to inflammation, flame height, and duration of inflammation.
  • the material according to the invention did not even catch fire, and easily attained the M1 and M2 classification with an effective index of 0/15 for M1 and 3.99/15 for M2 respectively, where an index of 15 indicates a product that is highly inflammable, and an index of 0 means a product that does not essentially catch fire.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

La présente invention concerne des compositions d'isolation non inflammable, thermique et phonique qui comprennent un mélange formé: d'un agent de liaison hydraulique, d'eau, de sable et d'un matériau caoutchouteux particulaire, ledit matériau caoutchouteux particulaire présentant une grosseur particulaire moyenne comprise entre environ 2 mm et environ 7 mm et sa présence correspondant à une proportion comprise entre environ 20% et environ 80% par rapport au volume total du mélange sec. Cette invention concerne également des éléments de construction et des procédés de préparation desdites compositions et de production desdits éléments de construction.
PCT/IB2002/004433 2001-10-23 2002-10-23 Compositions d'isolants non inflammables, thermiques et phoniques, elements de construction realises a partir de ces dernieres et procedes de production associes Ceased WO2003035571A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0114299A FR2831162B1 (fr) 2001-10-23 2001-10-23 Materiau d'isolation phonique et thermique
FR01/14299 2001-10-23

Publications (1)

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WO2003035571A1 true WO2003035571A1 (fr) 2003-05-01

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FR (1) FR2831162B1 (fr)
WO (1) WO2003035571A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017137980A1 (fr) * 2016-02-08 2017-08-17 Acogum Ltd. Compositions d'agrégats de caoutchouc permettant une atténuation acoustique

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040079259A1 (en) * 2002-10-29 2004-04-29 Felix Manig Method of manufacturing cementitious materials
WO2006027634A1 (fr) * 2004-06-30 2006-03-16 Alina Correa Materiau de construction qui presente une isolation amelioree contre le bruit, son procede d'obtention et ses utilisations
GB2529396B (en) * 2014-08-15 2021-09-01 Enviromate Ltd Anti-ballistic Structure

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2213034A1 (de) * 1971-03-19 1972-10-05 Orszagos Gumiipari Vall Warme und schallundurchlassige Betons, Mörtel beziehungsweise unter deren Verwendung erzeugte Bauelemente und Verfahren zur Herstellung dersel ben
WO1995018775A1 (fr) * 1994-01-10 1995-07-13 Tiremix Corporation Beton de ciment renforce avec des particules de caoutchouc
US5456751A (en) * 1993-09-03 1995-10-10 Trustees Of The University Of Pennsylvania Particulate rubber included concrete compositions
WO2000027774A1 (fr) * 1998-11-06 2000-05-18 University Of Utah Procede et composition pour ciment modifie au latex et renforce aux miettes de caoutchouc

Family Cites Families (4)

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Publication number Priority date Publication date Assignee Title
FR50140E (fr) 1938-12-31 1939-12-13 Gewerkschaft Keramchemie Berggarten Siershahn Westerwald Récipients, conduites, planchers et autres articles de structure stratifiée, étanches aux liquides et dont la surface est apte à résister aux actions mécaniques ouchimiques ou aux deux
FR1259487A (fr) 1960-03-16 1961-04-28 Sous-planchers
DE1669754C3 (de) 1968-02-14 1974-04-25 Basf Ag, 6700 Ludwigshafen Formmassen auf Basis von kautschukelastischen Polymerisaten, organischen Bindemitteln und gegebenenfalls mineralischen Füllstoffen
FR2437478A1 (fr) 1978-06-26 1980-04-25 Boulenger Ets Chape d'isolation phonique pour carrelage

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2213034A1 (de) * 1971-03-19 1972-10-05 Orszagos Gumiipari Vall Warme und schallundurchlassige Betons, Mörtel beziehungsweise unter deren Verwendung erzeugte Bauelemente und Verfahren zur Herstellung dersel ben
US5456751A (en) * 1993-09-03 1995-10-10 Trustees Of The University Of Pennsylvania Particulate rubber included concrete compositions
WO1995018775A1 (fr) * 1994-01-10 1995-07-13 Tiremix Corporation Beton de ciment renforce avec des particules de caoutchouc
WO2000027774A1 (fr) * 1998-11-06 2000-05-18 University Of Utah Procede et composition pour ciment modifie au latex et renforce aux miettes de caoutchouc

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
RAGHAVAN D ET AL: "WORKABILITY, MECHANICAL PROPERTIES, AND CHEMICAL STABILITY OF A RECYCLED TYRE RUBBER-FILLED CEMENTITIOUS COMPOSITE", JOURNAL OF MATERIALS SCIENCE, CHAPMAN AND HALL LTD. LONDON, GB, vol. 33, no. 7, 1 April 1998 (1998-04-01), pages 1745 - 1752, XP000740521, ISSN: 0022-2461 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017137980A1 (fr) * 2016-02-08 2017-08-17 Acogum Ltd. Compositions d'agrégats de caoutchouc permettant une atténuation acoustique

Also Published As

Publication number Publication date
FR2831162A1 (fr) 2003-04-25
FR2831162B1 (fr) 2004-12-17

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