ILLÉS, Róbert (Toldi u. 6, Szolnok, H-5000, HU)
BAWADIKJI, Souhil (lparos u. 86/A, Érd, H-2030, HU)
FELFÖLDI, lmre (Szári u. 28, Felcsύt, H-8086, HU)
VÁRFALVI, János (Szabadság ύt 4, Diόsjenő, H-2643, HU)
ILLÉS, Róbert (Toldi u. 6, Szolnok, H-5000, HU)
| CLAIMS: 1. Building material using cellulose, the plastic mixture before hardening of said building material contains cellulose raw material, in particular shredded paper, as well as water and bonding agent, mainly cement and at least one additive and a solid end product is formed from the afterhardening mixture, characterized by that, the quantity of the cellulose raw material in the plastic mixture of the building material correlated with 1 m3 of the hardened end product is above 30 kg, preferably 30-150 kg, from which the shredded paper is at least 20 kg, preferably 20-60 kg and this paper raw material is ground cotton-like paper flakes, furthermore, the mixture contains at least 10 kg. preferably 10-20 kg dispersion emulsion additive of alkaline-siloxane and/or acrylate base. 2. Building material according to claim 1, characterized by that, the paper flakes are preferably produced from mixed paper, ground to identical flakes size with the use of a rotary knife grinding mill. 3. Building material according to claims 1 or 2, characterized by that, the plastic mixture of the building material correlated with Im3 of the set end product contains at least 0.3 kg, preferably 0.3 - 0.6 kg mixture-gelling agent, preferably methylcellulose. 4. Building material according to any of claims 1-3, characterized by that, the density of the hardened end product made from the building material is 160-1700 kg/m . 5. Method for production of building material according to any of claims 1-4, characterized by that, during the production of the building material as raw material: material with cellulose content, preferably flocculated paper and/or wood are used, as dry additive: preferably river sand and/or graded gravel, and/or boron compound, and/or methylcellulose and/or limestone dust and/or pearlite are used, as bonding agent: cement or gypsum are used, as fluid additive: fluid dispersion emulsion, preferably fluid alkaline-siloxane base and/or acrylate base dispersion emulsion are used, as well as water is used. 6. Method according to claim 5, characterized by that, during the production of moist plaster, first the fluid dispersion emulsion is added to the water in the wet mixing space, preferably in a concrete mixer, then the coarse-grained additives, then during continuous mixing the raw material of cellulose content is added, then finally the bonding agent, and so the preferably homogenously mixed mixture is used as required. 7. Method according to claim 5, characterized by that, for producing the semi-finished dry building material-mixture, dry building material-mixture is made in a closed, dry mixing space with air circulation technology, in such a way, that first the raw material of cellulose content is put into the mixing space, then from among the dry additives first the pearlite, and in given case the bonding agent, that are preferably homogenously mixed with air circulation, then the additional solid additives of bigger density are added to this mixture in a further dry mixer, also with dry mixing, and the preferably homogenously mixed mixture is packed, transported, or stored, then for the application the dry building material-mixture is homogenously mixed by adding the fluid additives and water, and is used as required. 8. Method according to any of claims 5-7, characterized by that, as paper raw material of cellulose content, any solid paper, arisen during production of paper, or press products, which is useless for other purposes, or any newspaper, paper product, cardboard, mixed office paper, sorted out written documentation, or drawings, domestic, commercial or industrial recyclable paper waste etc. can be used, and the paper raw materials are collected and delivered to a central paper processing plant, where dry, cotton-like paper flakes of constant size, identical consistency, and volume weight are produced in a paper-grinding-flocculating mill, as wood raw material, fine wood dust, sawdust made from wood, unsuitable for building, or from wood waste, or dust produced during making wooden products, can be used. 9. Method according to any of claims 5-7, characterized by that, as dry additive - river sand, and/or graded gravel, and/or polystyrene pearl, and/or plastic grits, and/or brick grist of particle size of 0 - 3.0 mm, - boron compound, used as fiame-retardant agent necessary from fire-protection aspect for storing dry building materials, - methylcellulose: chemically neutral material (chemical identification: E461) white, or brownish hydrophil powder made from cellulose (eg. corn, or flax), - limestone dust, preferably building industry limestone dust, - pearlite: pearlite for general use in construction or hydrophobic pearlite are used. 10. Method according to any of claims 5-7, characterized by that, as bonding agent - cement: preferably mainly white or grey cement of great strength (between 42.5 - 52.5), but in given case it could be cement of 32.5, - gypsum: in given case a gypsum mixture of hardness of grade III can be used. 11. Method according to any of claims 5-7, characterized by that, a dispersion emulsion containing solvent-free alkaline-siloxane and/or silicic acid of acrylate base are used as dispersion emulsion, which can be regarded a socalled secondary bonding agent as well. 12. Method according to any of claims 5-11, characterized by that, at the prefabrication, or on-site pouring of the products, elements made from the building material-mixture according to the invention, the pouring time can be regulated between wide ranges with the dispersion emulsion additive applied as emulsion, namely, eg. the setting time, that is the hardening time of the product can be determined between one hour to 24 hours. 13. Method according to any of claims 5-12, characterized by that, the processing of the paper takes place in a closed system rotary knife grinding mill, and during the process cotton-like paper flakes of identical size are produced. 14. Method for application of the building material according to any of claims 1-4, as well as application of building material produced by the method according to any of claims 5-13, characterized by that, general purpose construction ready-made products, in given case bricks, beams, monolith steps, loadbearing walling elements, blocks, bars, columns, shutterings, chisel works as well as plastering, insulating and glueing materials, correcting material, plasters can be made from the building material. 15. Method for application of the building material according to any of claims 1-4, as well as application of building material produced by the method according to any of claims 5-13, characterized by that, in case of on-site application, monolith building structures, cast on-site are produced, eg. ceilings, heat,-and sound insulating monolithic underlays. |
and application thereof
The subject of the invention is a building material using cellulose, and method for producing and application thereof, said light-weight building material contains cellulose raw material and natural additive materials, and which can be mainly applied as afterhardening building material in structural architecture and civil engineering for several different tasks, so eg. for loadbearing walling elements, blocks, beams, columns, shutterings, monolithic structures, eg. ceilings, heat,- and sound-insulating underlays, chisel works, as well as for plastering, insulating and adhesive mortars.
It has been known for long in common trade a heat insulating material of cellulose raw material (eg. under the name of ISOCELL) which is made from newspapers with adding a boron compound. This bulk heat insulating material consisting of small pieces is put among the spaces and gaps of beams and frame-columns by manual spreading or mechanized blowing (see eg: www.foek.hu).
According to practical experiences the drawback of the above insulating material and technology is, that the packing factor of the insulating material does not remain steady, if water or any liquid gets to the system through the gaps of the closed building boards, or through the building panels themselves. It results in the breaking down of the insulating material, that is the definite loss of insulating ability. Therefore it is irreparable, and it can be made good only by rebuilding the walls, in a very expensive way. On the other hand the above solution is exclusively based on newspaper treating, it is expensive and not environmental-friendly enough, it can not take into consideration the other recyclable, cheap papers.
The EP- 127575 patent description makes known such a light-weight building material for the production of asbestos-free wall-, or ceiling-covering boards, where the weight ratio of the water, paper and cement in the plastic mixture before setting is 1000 : 100 : 750, and where the surface of the pieces of paper is of 0.5 cm 2 size. The cutting of the paper is made by tearing, and the pieces of paper are soaked in lime cream before adding it to the mixture.
In case of traditional building materials of cellulose base, the main problem in practice is, that the cellulose raw material, primarily the paper, should be treated beforehand with an expensive and elaborate chemical process to achieve a satisfactory bonding with the bonding material, mainly with cement.
Practical findings show however, that even in case of careful and professional chemical treatment the sufficient bonding can not be guaranteed, consequently not the prescribed strength of the end product either. Therefore it is often necessary to add auxiliary reinforcing fibre-materials to the mixture to increase the strength of the end product. It results in additional material and processing cost increase, further increasing the price of the end product, on the other hand it makes production technology more complicated, at the same time the required effect of increase of strength is missed in spite of the special efforts, so the products made this way generally do not conform with the current level of higher strength requirements of building materials.
It is an important requirement in case of light-weight concrete to increase the strength parameters of the end product, as this is one of the hindrances of using them more widespread.
The other important problem with the traditional solutions is, that the ratio of cellulose, eg. the paper raw material in the mixture can be increased to a limited extent only, unfortunately limiting the increase of the important parameters of the building material, namely the heat and sound insulation.
We aim to eliminate the above discrepancies with the present invention, that is to produce an improved light-weight building material of cellulose content, where on the one hand the heat insulating characteristics of the end product can be increased, on the other hand the strength of the same can be increased accurately planned, effectively, conforming with the most up-to-date requirements.
Our further aim is to decrease the weight of the end product to be made of light-weight building material. Also a further aim is to create a light-weight building material of special cellulose content, from which even a range of products can be created resulting in the fact, that the different requirements of structural architecture and civil engineering can be economically met at a high technical-technological level.
The basis of the solution according to the invention is the realization, that the set aim can be achieved, if we give up the cutting method of traditional technologies of tearing paper, and instead paper-flakes of cotton-like raw material is applied by using a special mixture-compound, on the other hand in an original way we use a special dispersion emulsion as additive to the mixture. Essentially due to these arrangements it is astonishingly possible to meet the complex requirement-system regarding on the one hand the improvement of the insulating and strength parameters, on the other hand the radical dicrease of the weight of the end product.
The invention is such a special building material, that is a plastic mixture containing cellulose raw material, mostly chopped paper, as well as water and bonding agent, mainly cement, and at least one additive before it hardens and the solid end product is formed from the afterhardening mixture. The essence of the solution according to the invention is, that the quantity of the cellulose raw material in the plastic mixture correlated with 1 m 3 of the hardened end product, is above 30 kg, preferably 30-150 kg, from which the chopped paper is at least 20 kg, preferably 20-60 kg and this paper raw material is ground into cotton-like paper flakes. Furthermore, the mixture contains at least 10 kg, preferably 10-20 kg dispersion emulsion additive of alkaline-siloxane and/or acrylate base.
An additional characteristic of the solution according to the invention is, that the paper flakes of same size are preferably produced from mixed paper, with the use of a rotary knife grinding mill with air circulation. It is of great importance from the point of view of the setting of the building material, the flexibility and strength of the end product, which will be described below in details.
The plastic mixture of the building material correlated with 1 m 3 of the hardened end product preferably contains at least 0.3 kg, preferably 0.3-0.6 kg gelling agent, preferably methylcellulose, the special effects of which will be discussed later in detail as well.
The solution according to the invention ensures to produce a range of products essentially on basis of identical formula with the prescribed quantities of the components, where the density of the hardened light-weight end product made of the recommended light-weight building material can be between 160-1700 kg/m . This way the field of application of the building material according to the invention is considerably extended.
Furthermore the invention is method for production of building material, which is characterized by that, during the production of the building material as raw material : material with cellulose content, preferably flocculated paper and/or wood are used, as dry additive: preferably river sand and/or graded gravel, and/or boron compound, and/or methylcellulose and/or limestone dust and/or pearlite are used, as bonding agent: cement or gypsum are used, as fluid additive: fluid dispersion emulsion, preferably fluid alkaline-siloxane base and/or acrylate base dispersion emulsion are used, as well as water is used.
In one preferred realization of the method according to the invention, during the production of moist plaster, first the fluid dispersion emulsion is added to the water in the wet mixing space, preferably in a concrete mixer, then the coarse-grained additives, then during continuous mixing the raw material of cellulose content is added, then finally the bonding agent, and so the preferably homogenously mixed mixture is used as required.
In another preferred realization of the method according to the invention, for producing the semi-finished dry building material-mixture, dry building material-mixture is made in a closed, dry mixing space with air circulation technology, in such a way, that first the raw material of cellulose content is put into the mixing space, then from among the dry additives first the pearlite, and in given case the bonding agent, that are preferably homogenously mixed with air circulation, then the additional solid additives of bigger density are added to this mixture in a further dry mixer, also with dry mixing, and the preferably homogenously mixed mixture is packed, transported, or stored, then for the application the dry building material-mixture is homogenously mixed by adding the fluid additives and water, and is used as required.
In a further preferred realization of the method according to the invention, as paper raw material of cellulose content, any solid paper, arisen during production of paper, or press products, which is useless for other purposes, or any newspaper, paper product, cardboard, mixed office paper, sorted out written documentation, or drawings, domestic, commercial or industrial recyclable paper waste etc. can be used, and the paper raw materials are collected and delivered to a central paper processing plant, where dry, cotton-like paper flakes of constant size, identical consistency, and volume weight are produced in a paper-grinding-flocculating mill, as wood raw material, fine wood dust, sawdust made from wood, unsuitable for building, or from wood waste, or dust produced during making wooden products, can be used.
In a further preferred realization of the method according to the invention, as dry additive
- river sand, and/or graded gravel, and/or polystyrene pearl, and/or plastic grits, and/or brick grist of particle size of 0 - 3.0 mm,
- boron compound, used as flame-retardant agent necessary from fire-protection aspect for storing dry building materials,
- methylcellulose: chemically neutral material (chemical identification: E461) white, or brownish hydrophil powder made from cellulose (eg. corn, or flax),
- limestone dust, preferably building industry limestone dust,
- pearlite: pearlite for general use in construction or hydrophobic pearlite are used.
In a further preferred realization of the method according to the invention, as bonding agent
- cement: preferably mainly white or grey cement of great strength (between 42.5 - 52.5), but in given case it could be cement of 32.5,
- gypsum: in given case a gypsum mixture of hardness of grade III can be used.
In a further preferred realization of the method according to the invention, a dispersion emulsion containing solvent-free alkaline-siloxane and/or silicic acid of acrylate base are used as dispersion emulsion, which can be regarded a socalled secondary bonding agent as well.
In a further preferred realization of the method according to the invention, at the prefabrication, or on-site pouring of the products, elements made from the building material-mixture according to the invention, the pouring time can be regulated between wide ranges with the dispersion emulsion additive applied as emulsion, namely, eg. the setting time, that is the hardening time of the product can be determined between one hour to 24 hours.
In a further preferred realization of the method according to the invention, the processing of the paper takes place in a closed system rotary knife grinding mill, and during the process cotton-like paper flakes of identical size are produced.
Furthermore the invention is method for application of the building material, in the course of which general purpose construction ready-made products, in given case bricks, beams, monolith steps, loadbearing walling elements, blocks, bars, columns, shutterings, chisel works as well as plastering, insulating and glueing materials, correcting material, plasters can be made from the building material. Furthermore the invention is method for application of the building material, in the course of which in case of on-site application, monolith building structures, cast on-site are produced, eg. ceilings, heat,-and sound insulating monolithic underlays.
In order to describe the solution according to the invention in more details, at first we discuss the raw materials and additives of the light-weight building material on basis of the findings of widespread research and experiments.
l.RAW MATERIALS OF CELLULOSE CONTENT
a) Paper:
As paper raw material, any solid paper available during production of paper, or press products, which is useless for other purposes, or any newspaper, paper product, cardboard, mixed office paper, written documentation, or drawings, domestic, commercial or industrial recyclable paper waste, etc. can be used.
The paper raw materials are collected and delivered to a central paper processing plant, where dry, cotton-like paper flakes of constant size, identical state and volume weight are produced in a paper-grinding, flocculator mill. Preferably a closed system of rotary knife grinding mill with air circulation is used for this purpose.
b) Wood material:
This can be any wood material, especially those useless for building, fine wood grinding sawdust, ground wood waste, or wood dust produced during production of wood products.
2. DRY ADDITIVES:
a) River sand,
b) Graded gravel, pearlite, polystyrene pearl, or plastic grits of particle size between 0 and 3.0 mm,
c) Boron compound:
When storing dry building materials it has a role of ignition inhibitor from the aspect of protection against fire.
d) Methylcellulose:
It is a chemically neutral material (chemical identifying sign: E461) produced from cellulose (eg. from corn or flax) it is white, or brownish hydrophil powder, whose main role is to increase the viscosity of the mixture, which is executed by making it slightly gelatinous. It has great importance for the purpose of the invention, that the different fractions in the mixture do not get separated, but they essentially ,,stay in place in the mixture".
Furthermore, it serves as secondary adhesive as well. Besides the above its important feature is, that it solves in water, however it prevents sudden water take up of the paper and sawdust. Its task to protect cement-bonding mixtures from sudden dehydration, considerably decreasing the tendency of the end product to being cracked also should be highlighted.
3. BONDING MATERIALS:
a) Cement: it can be mainly of high strength, (between 42.5 - 52.5) white, or grey cement, but in given case good results can be achieved with cement of 32.5 strength. b) Plaster/gypsum: it can be eg. gypsum mixture of grade III hardness.
4. EMULSIONS:
In the sense of the present invention the emulsion additives have a highlighted importance. Their material, application, role, necessity and importance in the building materials according to the invention is shown in the description below.
Dispersion emulsions could be:
a) Additives added to liquid dispersion base of alkaline-siloxane basis. No new compound is created here, but they can be considered socalled secondary bonding materials in the building material-mixture according to the invention.
b) Additives added to dispersion base of acrilate basis, where no new compound is created, but they can be also considered socalled secondary bonding materials in the building material-mixture according to the invention.
The function, peculiar technical additional effect of the dispersion emulsions:
- In case of building materials of gypsum bonding
- At the prefabrication or on-site pouring of the products, elements made from the building material-mixture according to the invention, the time of pouring can be regulated within broad limits with the help of the emulsion additive, namely, eg. the setting, that is the hardening time of the product can be regulated from one hour to 24 hours, resulting in an invaluable technological flexibility and advantage for the builder;
- The emulsion applied transforms the paper flakes, pearlite and sawdust in the building material-mixture into a homogenous, pulpy material, so it is possible, that eg. a building material-mixture, eg. plaster, cast into a negative mold becomes an accurate and true copy of the mold;
- The emulsion additive makes the mixture hydrophobic the extent of which can be regulated; by this it can be guaranteed, eg. the weather-proofness of outdoor products;
- In case of interior plasters the emulsion ensures sufficient adhesion and resulting from its foaming effect the material thickness of a single application can even be 3-4 cm, increasing productivity considerably; - The foaming effect of the emulsion can be used in given case for creating air-cells in the building material to further increase its insulating parameters, that can be planned in advance.
In case of cement-bonding building materials:
- Essentially the highlighted technical effects mentioned in case of the gypsum-bonding products are valid here as well;
- The flexibility of the monolith structures made of cement-bonding building materials is increased, as well as the outdoor cast light-weight concrete products are protected from sudden drying up, that is from quick dehydration, and this way the unwanted crackedness of the product can be prevented, so the post-treatment, eg. watering can be saved.
An important auxiliary technical added effect of the emulsion according to the invention in case of all building materials made with both of the above described bonding materials is, that
- the emulsion plays a decisive role in the determination of the density of the building material-mixture; values between 200 kg/m 3 and 1700 kg/m 3 can be achieved with the use of it, which is practically unfeasible using the traditional solutions;
- the emulsion decreases the hydration of the raw materials (paper, sawdust) of normally high liquid absorption ability, primarily that of the paper;
- with the application of the emulsions according to the invention we achieved for the first time, that overcoming the technical limit existing till now, a much bigger quantity of cellulose, partly paper flakes, even 150 kg of it could be poured in 1 m 3 building material, resulting in an extraordinary increase of the parameters of heat,-and sound- insulation of the product according to the findings of our experiments.
As it can be concluded from the above, various combinations of the components of the building material of cellulose content according to the invention, detailed above make possible the creation of building material end products of different properties, which properties can be determined in advance. Here the strength of the product can be increased even from C8 to C25, the density of the product can be significantly decreased, depending on the sort of application, even between values of 160-1,700 kg/m 3 namely really ,,light-weight" building materials can be made.
We will bring examples below for these, but it must be highlighted, that it is possible to realize several different finish forms, versions and combinations within the required patent range, beyond the examples that are not mentioned here due to limits of footage, but they will be obvious to persons skilled in the art.
The invention is made known in more details on basis of the examples of realization below, in which a few examples of the solution according to the invention, sort of application as well as production technology are described. By way of introduction, for the purpose of this invention, it is to be highlighted, that as raw material of the light-weight building material according to the invention, an increased proportion of cellulose, compared to the state of the art is used, a great proportion of which is produced from paper, eg. mixed paper, in given case recycled paper. The remain part of the cellulose raw material is sawdust made from any wood type.
The processing of the paper - contrary to traditionally used paper tearing or grinding to dust - is made in a closed system rotary knife grinding mill, and during this process (cotton-like) paper flakes of identical size are produced. The paper flakes of identical size has of great importance from the point of view of especially improved bonding with the bonding material, increased insulation values and extraordinary flexibility of the solid end product.
In the examples below solvent-free dispersion emulsions of silicic acid content of alkaline-siloxane or acrylic base are used as ,,emulsion". Resulting mainly from this fact, for the purpose of this invention, it is to be noted, that the cellulose content can be according to our experimental findings, increased to 180 kg/m 3 from the 80 kg/m considered so far the possible maximum in the art.
It results in the additional surprising effect for the persons skilled in the art, that partly the mass of the product can be radically decreased, partly the heat,-and sound insulating characteristics are much improved, so the most modern insulation requirements can be easily met at relatively low costs.
I. BUILDING MATERIAL OF CELLULOSE BASE FOR LOADBEARING STRUCTURAL ELEMENTS, PARTS
In this chapter we will describe a few forms of realization of the building material of cellulose base according to the invention in applications in loadbearing structures, respectively in that of those parts, and which are for example reinforced, or unreinforced light-weight concrete elements, so e.g. wall elements, blocks, ceiling elements, shuttering elements and likes that can be poured with conventional manual or mechanical technologies.
According to our findings, summing up these building materials of cellulose base according to the invention, for example the light-weight concretes with cement bonding agent have the following main parameters and characteristics:
- The consistency of the building material-mixture before pouring: medium plastic
- Mass: 800 kg/m 3 - 1700 kg/m 3
- Recommended thickness: 9.0 - 40.0 cm.
- Homogenous structure,
- Excellent heat,- and sound insulating ability,
- The mouldable mixture is dehydrated slowly after pouring, that is, in the setting phase, with minimal shrinking, - The surface can be walked on after 24 hours of the pouring of the mixture, it can be loaded after 14 days,
- The end product is 40-50% lighter, than the conventional concrete, or reinforced concrete product,
- It is much more flexible, than the conventional concrete, or reinforced concrete,
- Resulting from the use of raw material of cellulose base the end product tolerates well big fluctuation of heat
EXAMPLE I/I
A wall block was made from the light-weight building material according to the invention. We used the following formula for this:
Content of solid matter correlated with 1 m 3 of the end product:
- Paper flakes 35 kg
- Sawdust 25 kg
- Pearlite 10 kg
- Gravel (0-5mm) 460 kg
- Cement (42.5) 400 kg
- Methylcellulose 0.3 kg
Total solid material mass: 930.3 kg,
Fluid content correlated with 1 m 3 of end product:
- Water 530 kg
- Emulsion 20 kg.
The total weight of the homogenous pourable building material-mixture is 1 ,480 kg, its consistency was of medium plastic. The weight of Im 3 of the set end product was appr. 1 ,000 kg, strength between C20 - C 25.
Furthermore eg. reinforced concrete steps, so called coffin ceilings, reinforced concrete crownings, artificial stone castings, statues, reinforced concrete shrinking and flexible concretes can be made from the above mixture.
In case of the building material according to the invention depicted in the present example, the order of the process of mixture making can be the following:
- first the dry paper flakes, the sawdust, pearlite and methylcellulose are added to the wet gravel, scree during continuous mixing,
- then the prescribed quantity of water and dispersion emulsion is mixed to the homogenized material, and finally
- the definite mixture is formed by adding cement to it.
But in given case making of the afterhardening material can be done in such a way as well, that
- first the dry components mentioned above are homogenized in a closed space mixture,
- the dispersion emulsion is added to the water portion, and finally
- the dry material mixture is added to the solution prepared this way. The plastic and mouldable mixture produced this way is poured within one hour. It can happen by pressing the mixture into a shape/form eg. during production of wall blocks.
After pressing the product can be taken out, that is it is in a state, when it can be dismantled. Setting time is 10-15 days, it needs no after-treatment, eg. watering. Its shrinking coefficient is better, than those of conventional concrete products.
EXAMPLE 1/2
Here pillars, respectively columns were made as examples of realization. But in given case the same mixture is suitable for making eg. reinforced concrete flat, arched, slant ceilings, special reinforced concrete shell roof structures, underground reinforced concrete engineering structures, prefabricated reinforced concrete elements of structural architecture and civil engineering, prefabricated and on-site reinforced concrete elements for bridge-building and hydraulic engineering.
In case of this example of realization the solid material content correlated with Im 3 end product was the following:
- Paper flakes 20 kg
- Sawdust 20 kg
- River sand 300 kg
- Gravel (0-5 mm) 780 kg
- Cement (52.5) 500 kg
- Methylcellulose 0.3 kg
Total solid material mass: 1 ,620.3 kg.
Fluid content correlated with Im 3 of end product:
- Water 450 kg
- Emulsion 10 kg.
The total weight of the homogenous, pourable building material-mixture was 2,080 kg, its consistency was medium plastic.
The weight of the set end product of 1 m 3 was 1,700 kg, strength between C23 - C25.
II. BUILDING MATERIAL OF CELLULOSE CONTENT, MAINLY LIGHTWEIGHT CONCRETE, ESPECIALLY FOR UNDERLAYS, LIGHT-WEIGHT
RECEDE CONCRETES, CRUST CONCRETES AND ALIKE
According to our findings these building materials of cellulose base according to the invention, for example the mouldable, plastic mixture of light-weight concretes made with cement bonding agent can be poured with conventional technologies, eg. for loadbearing underlays, cast heat,-and sound insulated wallings, tread-proof heat- insulating ceiling plates, flat roofs and alike, and all these have the following main common parameters and characteristics:
- The consistency of the lightweight concrete mixture before pouring is medium plastic,
- Mass: 250 - 1 ,000 kg/m 3 , - Thickness: 2.0 - 40.0 cm,
- Homogenous structure,
- Excellent heat,-and sound insulating ability (K= 0.25-0.4 WAn 2 K), therefore the auxiliary plastic insulating sheets for heat insulation and tread proofness can be omitted,
- After pouring, that is during the setting phase it loses its water content slowly with minimal shrinking,
- It does not require aftertreatment (eg. watering),
- The surface can be walked on after 48 hours of the pouring of the mouldable mixture, it can be loaded after 14 days,
- The end product is 40-50% lighter, than the conventional concrete, or reinforced concrete product,
- It is much more flexible, than the conventional concrete, or reinforced concrete,
- The end product tolerates well big fluctuations of heat as well.
EXAMPLE II/l
Loadbearing heat,-and sound insulating walling was made from the light-weight building material according to the invention.
Solid material content correlated with 1 m 3 end product:
- Paper flakes 20 kg
- Sawdust 20 kg
- Plastic granules (0-3 mm) 10 kg
- Cement (42.5) 400 kg
- Methylcellulose 0.6 kg
Total solid material mass: 450.6 kg,
Fluid content correlated with 1 m 3 of end product:
- Water 400 kg
- Emulsion 10 kg.
The total weight of the ready, pourable building material-mixture is 860 kg, its consistency was medium plastic. The weight of the set end product was 500 kg.
EXAMPLE II/2
In case of the example of this realization also a loadbearing heat,-and sound insulating wall was made from the light-weight building material according to the invention.
Solid material content correlated with Im 3 solid end product:
- Paper flakes 40 kg
- Sawdust 60 kg
- Pearlite 30 kg
- Gravel (0-5 mm) 370 kg
- Cement (42.5): 400 kg
- Methylcellulose 0.3 kg
Total solid material mass: 900.3 kg, Fluid content correlated with 1 m 3 of end product:
- Water 600 kg
- Emulsion 10 kg.
The total weight of the homogenous building material-mixture is 1,510 kg, its consistency was medium plastic before pouring. The weight of the set 1 m end product was appr.1 ,000 kg.
III. BUILDING MATERIAL OF CELLULOSE CONTENT FOR LIGHT-WEIGHT CONCRETE PRODUCTS MADE BY CAST AND COMPACTED TECHNOLOGIES
The mouldable, plastic mixture of these light-weight building materials of cellulose base according to the invention with improved heat,-and sound insulating can be poured according to our findings as cast and compacted products, respectively a range of products with conventional technologies in solid, as well as of air pore finish.
Cement and/or gypsum was used as bonding agents and acrylate and/or siloxane base products were used as suspensions.
Examples of fields of application:
- Shutter boards for shuttering systems,
- for casting flat, or arched ceilings,
- for arched columns, respectively pillars of spheric or any other profiles,
- for single operational (buried) applications, after it is definitely well set to the cast plasters,
- as definite interior or exterior surface treating element,
- as exterior and interior heat,- and sound insulating plates,
- as coverings of improved heat,-and sound insulation, as walling element,
- in case of reconstruction of facades of historical monuments for making missing ornaments, inserts, statues and platforms,
- for coverings of stone,- and wood-imitations, boards, respectively blocks.
These materials have the following main parameters and characteristics:
- The consistency of the light-weight concrete mixture before pouring is: medium plastic.
- Mass: 160 - 1,000 kg/m 3 ,
- Thickness: 1.0 - 50.0 cm,
- Excellent heat,-and sound insulating ability (K= 0.25-0.40 W/m 2 K).
EXAMPLE III/l
Here the shuttering boards were made in a thickness of 8 cm with the following mixture composition:
Solid material content correlated with 1 m 3 end product:
- Paper flakes 60 kg
- Sawdust 90 kg
- Pearlite 15 kg
- Cement (42.5): 400 kg - Methylcellulose 0.3 kg
Total solid material mass: 565.3 kg.
Fluid components:
- Water 400 kg,
- Emulsion 20 kg (of acrylate and/or siloxane base).
The total weight of the homogenous, pourable building material-mixture is 985 kg, and its consistency was medium plastic. The weight of the set 1 m end product was appr.650 kg.
EXAMPLE ffl/2
In case of this example insulating boards of 6 cm thickness were produced from the following mixture:
Solid material content correlated with 1 m 3 end product:
- Paper flakes 45 kg
- Sawdust 65 kg
- Gypsum: 280 kg
- Methylcellulose 0.3 kg
Total solid material mass: 390.3 kg.
Fluid content :
- Water 400 kg
- Emulsion 20 kg.
The total weight of the ready building material-mixture was 810 kg, its consistency was medium plastic. The weight of the set 1 m 3 end product was appr.460 kg.
EXAMPLE III/3
In case of this example of realization insulating boards were made as well, but in thickness of 12 cm with the following formula:
Solid material content correlated with 1 m end product:
- Paper flakes 50 kg
- Pearlite 25 kg
- Plastic granules 10 kg
- Gypsum: 70 kg
- Methylcellulose 0.3 kg
Total solid material mass: 155.3 kg.
Fluid content correlated with 1 m 3 :
- Water 400 kg
- Emulsion 20 kg.
The total weight of the ready building material-mixture was 575 kg, its consistency was medium plastic, castable. The weight of the set end product was 160 kg. EXAMPLE III/4
Here brick-like walling elements were made with the following mixture-composition:
Solid material content correlated with 1 m 3 end product:
- Paper flakes 45 kg
- Pearl ite 20 kg
- Sawdust 80 kg
- Gravel (0-3 mm) 390 kg
- Cement (42.5) 400 kg
- Methylcellulose 0.3 kg
Total solid material mass: 935.3 kg.
Fluid content correlated with 1 m 3 :
- Water 550 kg
- Emulsion 20 kg.
The total weight of the ready building material-mixture was 1,505 kg, its consistency was medium plastic, compacted (moist concrete). The weight of the set 1 m 3 end product was 1 ,000 kg.
EXAMPLE III/5
Here chisel-work elements were made from the building material according to the invention with the mixture-composition below:
Solid material content correlated with 1 m 3 end product:
- Paper flakes 30 kg
- Pearlite 70 kg
- Gypsum 250 kg
- Methylcellulose 0.3 kg
Total solid material mass: 350.3 kg.
Fluid content correlated with 1 m 3 :
- Water 500 kg
- Emulsion 20 kg.
The total weight of the homogenous, pourable building material mixture was 870 kg, its consistency was medium plastic, castable well. The weight of the set 1 m 3 end product was 400 kg.
IV. BUILDING MATERIAL OF CELLULOSE BASE, MAINLY FOR PLASTER FOR WALLS AND ADHESIVES
The plastic mixture of the plasters, that can be applied manually or mechanically, according to our findings belong to this group of building materials of cellulose base according to the invention.
In case of these materials cement and/or gypsum was used as bonding agents and acrylate and/or siloxane base products as suspension. These plasters have the following main common parameters and characteristics:
- The consistency of the light-weight concrete mixture before pouring: medium plastic, that is castable,
- Mass: 160 - 500 kg/m 3
- Thickness: 1.0 - 10.0 cm.
- Excellent heat,- and sound insulating ability,
- Field of application:
- eg. for plastering exterior or interior surfaces with short setting time, single application layer thickness is preferably 2-4 cm, it does not crack, has good heat- storing characteristics, as well as can be painted and wallpapered, or
- for adhesion of ceramic tiles and wooden covering plates, eg. it considerably decreases knocking on ceilings.
EXAMPLE IV/1
Here plaster for interior walls was made from the building material according to the invention with the following mixture-composition:
Solid material content correlated with 1 m end product:
- Paper flakes 40 kg
- Pearlite 60 kg
- Gypsum 200 kg
- Methylcellulose 0.3 kg
Total solid material mass: 300.3 kg.
Fluid content correlated with 1 m 3 :
- Water 400 kg
- Emulsion 10 kg.
The total weight of the homogenous building material-mixture was 710 kg, its consistency was medium plastic. The weight of the set 1 m 3 end product was appr. 320 kg-
EXAMPLE IV/2
This case plaster for exterior facades was made from building material of cellulose content according to the invention.
Solid material content correlated with 1 m 3 end product:
- Paper flakes 35 kg
- Pearlite 20 kg
- Plastic granules (0-3 mm) 10 kg
- Cement (42.5) 350 kg
- Methylcellulose 0.6 kg
Total solid material mass: 415.6 kg.
Fluid content correlated with I m 3 :
- Water 400 kg
- Emulsion 10 kg. The total weight of the ready building material mixture was 825 kg, its consistency was medium plastic. The weight of the set Im 3 end product was 430 kg.
As it can be seen from the above examples, as well as from the findings of our lengthy experiments, the light-weight building material according to the invention can be applied widespread with the described advantageous effects both in structural architecture and civil engineering and these products can offer solutions to almost all problems of environmental protection and building technology.
In given case the swelling pearlite-mixture added to the cellulose flakes improves the heat insulation value of the products and promotes quick dehydration without any structural damage or additional work. As pearlite additive concretely:
- conventional building pearlite,
- hydrophobized pearlite
can be used.
Methylcellulose described above contributes to drying and setting of the building material, acting as auxiliary glueing and hardening agent between the cellulose fibres and pearlite, resulting in the improvement of the quality and strength of the end product.
The light-weight building material, especially the light-weight concrete elements recommended for loadbearing structures, according to the invention are competitive against the conventional brick or concrete regarding their strength and other characteristics, in many cases even exceeding those.
The excellent heat-insulation parameter of the range of products made from the building material according to the invention is to be highlighted, coupled with significant heat- storing capacity. According to our findings K- value of heat-insulation is strikingly advantageous, namely it can even achieve K= 0.25-0.40 WAn 2 K values, proving improved insulating features compared with the state of the art solutions. In modern building techniques good insulating characteristics will have inestimable economic importance due to radically increasing energy prices at present.
The lightweight wall structure or building element according to the invention has also a significant additional advantage, which resulting from its special heat-storing capacity, during daytime it takes up and during nighttime it egresses heat.
Moreover the sound-insulating feature of the building element according to the invention is also excellent, which is also of great importance from the point of view of inhabitant's peace and ambience in dwellings.
The light-weight building elements, structures, or layers according to the invention have great compression strength, coupled with strikingly high tensile strength, resulting also partly from the advantageous effect of paper flakes to bonding. It is to be noted that as it is well known, conventional concrete has low tensile strength, due to this it is necessary to provide it with reinforcements in an expensive and complicated way. The lightweight building material according to the invention is fireproof and waterproof, and it is resistant against damages caused by vegetable matter or pest, mildew fungis. In given case the disinfecting and fungicidal effect can be further increased by adding sal ammoniac to it.
A further important advantage of the light-weight building material according to the invention is, that its vapour permeable characteristic is outstanding, resulting in a pleasant climate and good feeling in the building, furthermore it is chemically neutral and non-corrosive.
Finally we have to highlight, that the strikingly small weight of the lightweight building material according to the invention results in significant transportation and building technology advantages. However this lightweight couples with strikingly high loadbearing.
Further significant advantage is, that the building physical properties of the lightweight building materials according to the invention can be altered between wide ranges, so it is possible to produce an almost ideal material for a given function. It makes possible in the construction industry for the first time to apply the socalled ,,reverse construction principle" namely, to produce the most possibly suitable material by virtue of the invention for a given structure, which was unthinkable in conventional construction practice. In conventional approach the traditional materials are given, so the structure must be adjusted to them obligately. In other words it means, that the possibilities of the constructor are limited, but this limiting obstacle is freed, solved by the present invention bringing considerable advantages for the future construction industry in our opinion.
In case of the solution according to the invention it is a further advantage, that only electricity is needed for the production, respectively devices functioning with electricity, there is no need to use gas or oil energy sources. The energy used for the production of the goods is only a fraction that of the energy needed for making similar building products. The building elements made from this building material can be glued with their own material, they can be plastered and repaired. Everything is made of the same kind of material.
It is a further advantage of the application, that brick bat gained during brick production or dismantling of buildings can be used as dry additive.