FUNCTIONALLY GRADED FOAM CONCRETE COMPOSITE WITH OPTIMIZED MECHANICAL AND ACOUSTIC PROPERTIES AND ITS PRODUCTION METHOD

Abstract

The invention relates to a three-layered functionally graded foamed concrete composite with varying density across the layers and its production method. The composite structure consists of a structural substrate designed in the density range of 800–1000 kg / m³, a mechanically and acoustically permeable intermediate layer in the density range of 600–800 kg / m³, and an acoustically active top layer designed in the density range of 300–600 kg / m³. Structural strength is achieved in the substrate through a low binder ratio and foam volume, while the noise reduction coefficient is improved in the top layer by increasing the foam volume, rubber aggregate ratio, and diatomite content. Pore stability, mechanical strength, and acoustic performance are all improved simultaneously through the use of cellulose fiber, fly ash, diatomite, and rubber aggregate in layer-specific proportions.The production method involves mixing cement-based binder, fly ash, diatomite, and cellulose fiber at specified mixing speeds; gradually adding foam produced using protein hydrolyzate, keratin derivatives, or animal protein-based foaming agents; and sequentially placing the bottom, middle, and top layer mixtures into the mold without mechanical vibration. This results in a functionally graded foamed concrete composite with a preserved pore structure and improved mechanical and acoustic performance, without segregation between layers.

Description

FUNCTIONAL WITH OPTIMIZED MECHANICAL AND ACOUSTIC PROPERTIES. GRADED FOAM CONCRETE COMPOSITE AND PRODUCTION METHOD TECHNICAL FIELD This invention has mechanical applications within the fields of building materials and civil engineering. enhanced durability while also providing high acoustic absorption performance. It relates to functionally graded lightweight foam concrete composite structure. PREVIOUS TECHNIQUE Lightweight foam concretes used in the current technical field are generally single-layered. These are materials with homogeneous density and limited functionality. Such foamed concretes, As a natural consequence of their high porosity, they offer a certain level of heat and sound insulation. Although they exhibit good performance, their mechanical strength is low and therefore they are structural. It is used in limited applications. Strength is increased by increasing density. When porosity is increased, it decreases, thus reducing noise. The coefficient of yield (CQ) decreases significantly. Most known studies show that strength and Acknowledging that there is an inevitable contrast between acoustic absorption and a single characteristic experimental studies focused on improvement or carried out with limited parameter variation. It is limited to certain approaches. The concept of functionally graded materials is used in some advanced composites. Although applied, foamed concrete specifically features a multi-layered density transition. by being created that simultaneously improves both mechanical behavior and acoustic absorption. A structural architecture that ensures harmony between layers has not been presented in the literature. The stepped density transition zone was not designed, and there were different additives in each layer. a holistic design approach that optimizes the interaction of different species There are none. Additives such as fly ash, diatomite, rubber aggregate and cellulose fiber are rarely used. Although involved in many studies, these contributions are used together, depending on the intensity. where performance is optimized on a layer-by-layer basis and mechanical properties are achieved within the same composite. A design system that preserves strength has not been systematically described. In terms of production methods, the current technique maintains high foam stability. prevents layers from collapsing or prevents mixtures of different densities from mixing together. It does not reveal a sequence of processes in which the material can be poured in a consistent manner. In the literature... The studies explore the mechanism of interconnecting a multilayered structure, layer transitions. 1 the pore structure of the region or the effect of this transition on acoustic performance It does not detail this. Therefore, the previous technique failed to provide both mechanical strength and... density-transition polynomials that combine noise reduction coefficients within the same material comprehensive and It cannot offer a viable solution. THE PURPOSE OF THE INVENTION The main purpose of the invention is to address the traditional structural weaknesses of lightweight foamed concrete. to eliminate and at the same time maintain high acoustic absorption performance To improve, the density and component content are determined across the layers. and a functionally graded composite structure modified according to component distribution. to obtain. The invention consists of three separate devices that meet different mechanical and acoustic requirements. the layers come together in an integrated and harmonious way within the same structural element By enabling this, both carrier behavior is improved and noise is reduced. It aims to create a material system in which the coefficient is increased. In this context, density-based additives such as fly ash, diatomite, rubber aggregate, and cellulose fiber The pore structure is controlled by improving it through layered architecture. A new foam in which layer transitions are stable and foam stability is maintained. Concrete design is presented. Another aim of the invention is to create a barrier between layers without causing collapse or separation. can be produced, and this simultaneously increases mechanical strength and acoustic performance. An innovative production method has been developed that makes its features transferable to a wide range of applications. The goal is to install it. Thus, both in structural elements and in architecture requiring acoustic insulation. and a multifunctional foamed concrete composite that can be used in industrial applications. It is being improved. DETAILED DESCRIPTION OF THE INVENTION The composite structure developed within the scope of the invention has different mechanical and other properties in each layer. designed to meet acoustic requirements, with density transition and as a functionally graded three-layer foamed concrete composite It is structured as follows: The composite structure in question consists of a substructure layer and a transitional layer. and three separate zones positioned in a sequential order, including the upper acoustic layer occurring and each of these regions has its own unique material composition, 2 It is formulated to have a specific pore structure and density range. This Thanks to the layered architecture, both load-bearing and mechanical functions are integrated within a single structural element. This ensures both the preservation of behavior and an increase in the noise reduction coefficient. Thus, the material is not only a lightweight concrete structure, but also It functions as a multifunctional building element with improved acoustic performance. The content used in the three-layer structure relates to the technical function of each layer. The relevant layer is selected based on its mechanical strength, pore stability, and sound absorption. and act as components that determine elastic damping properties. The binder phase ensures the continuity, setting behavior, and compressive strength of the foamed concrete matrix. It refers to the main mineral-based phase that provides its strength. Fly ash is the binder phase. It is included as a pozzolanic additive and increases the matrix's fill rate, late age Mineral additive that improves the strength and microstructural integrity of the binder phase. Diatomite is both lightweight and has a siliceous and naturally microporous structure. mineral filler as well as acoustic resonance and microporous sound absorption It is used as a functional additive that supports the mechanism. Foam volume, Determining the macroporosity ratio within the composite structure and reducing density. Fundamental in terms of thermal-acoustic insulation and attenuation of sound wave propagation. It acts as a parameter. Rubber aggregate, due to its elastomeric character. flexible aggregate phase that increases shock, vibration and acoustic energy damping capacity It is composed of cellulose fibers that support the stability of the foam walls, microscopically. limiting crack propagation and contributing to the preservation of interlayer integrity. It is used as a fiber supplement. In this context, the substrate has a high density and high binder content. With its structure, it forms the load-bearing region of the composite element, the middle layer is the base high rigidity behavior in the layer and acoustically active porous structure in the top layer It provides mechanical and acoustic transmission between them. The upper layer is low-density. With its high foam volume and structure containing rubber aggregate and diatomite, it allows sound waves to pass through openly. its spread within the porous structure, through internal friction and resonance effects It acts as an acoustically active region that enables attenuation. Thus, three layered structure, density, pore diameter, elastic behavior, and mineral admixture distribution It creates a graded composite in terms of load-bearing capacity and acoustics. It allows absorption functions to be performed simultaneously within the same material. It provides. 3 The substrate includes the binder phase, fly ash, diatomite, aggregate, and cellulose fiber. dry mix refers to the total of solid components excluding water and foam phase. containing 55–70% of the total binder by weight, and the foam volume... selected in the range of 10–20% of the total mixing volume, with a density of 800–1000 kg / m³. It is structured as a structural load-bearing zone designed within this range. In this zone The amount of fly ash should be 10–25% of the binder phase, and the amount of diatomite should be 5–15% of the binder phase. maintained within this range; thus, the matrix's fill rate and late-age strength Improvements are being made to ensure foam stability and prevent microcrack formation. To prevent this, the amount of cellulose fiber should be 0.10–0.50% of the total dry mix weight. The middle layer is selected within the range of 600–800 kg / m³ density. designed to function as a gradual transition between mechanical and acoustic properties. It has a pore structure created with an average pore diameter in the range of 0.5–2.0 mm. This is the region where the foam volume constitutes 20–35% of the total mix volume, and rubber aggregate. The amount is determined to be between 10–25% of the total aggregate volume. This ensures... The elastic modulus is gradually reduced and the acoustic energy dissipation capacity is decreased. Average pore diameter, foam volume and mixing parameters are being increased. It is formed by adjusting the thickness between 0.5–2.0 mm. Top layer; 300–600 kg / m³ It is an acoustically active zone designed within a density range. In this zone, the total foam volume... Mixture volume: 35–55%, rubber aggregate volume: 25–40% of total aggregate volume The amount of diatomite is selected to be in the range of 10–20% of the binder phase. (Regarding the top layer) The pore structure is finely dispersed, with an average pore diameter ranging from 0.1 to 1.0 mm. It is formed in the form of an open pore system. Natural particles ranging from 1–100 µm. With its siliceous structure containing micro-voids, diatomite contributes to acoustic resonance mechanisms. It increases the sound absorption capacity based on the stability of the foam walls. To maintain interlayer integrity, the amount of cellulose fiber in the total dry mix is... It is kept within the range of 0.15–0.60% of its weight. The layers are assembled through a specific manufacturing method. This is carried out. In the first stage of the production process, a cement-based binder and volatile oil are used. Ash, diatomite, and cellulose fiber are mixed dry in a mechanical tank operating at 60–120 rpm. Mix in the blender for 2-5 minutes until no visible lumps form. They are mixed in this way; as a result of this process, the additives are visibly present in the mixture. The water is then distributed in a way that prevents visible clumping. to be 0.35–0.55 water / binder ratio relative to the total binder amount It is added to the dry mix and the mixture is infused at a speed of 100–200 rpm for 2–4 minutes. 4 The fluid binder phase is obtained by processing. This consists of a bottom layer, a middle layer, and a top layer. Pre-fabricated foam is added to the binder phases prepared separately for each layer. The foam used consists of protein hydrolysate, keratin derivatives, and animal protein. protein-based foams containing foaming agents or combinations thereof It is obtained through the use of builder materials. In foam production, the foam density is 40–90. A foam generator is used to maintain a foam level within the g / L range. addition in three or more steps, in increments of 25–35% of the total foam volume. This is carried out by running the mixture at 50–150 rpm for 30–90 seconds after each addition. By stirring continuously for a certain period, the continuity of foam distribution is ensured. With this method... While achieving the specified density ranges, foam collapse is also prevented. Bottom, The middle and top layer mixtures are placed into the mold sequentially, and the placement process... Mechanical vibration is not applied during this period. Settlement occurs in layer transition zones. The fluidity of each layer is ensured to prevent separation or foam loss; The water / binder ratio, foam volume, and cellulose fiber content are adjusted together to achieve a foam thickness of 160–220 mm. The spreading diameter is kept within the specified range. This ensures interlayer adhesion. is provided and the pore structure exhibits a gradual transition across the layers. is provided. One of the key features of the invention is that functional grading is only not through density change; rubber aggregate, diatomite, fly ash and cellulose fiber achieved by systematically changing the layer-specific ratios. It is formed by rubber aggregate, which, thanks to its viscoelastic behavior, reduces vibration and sound. It contributes to the dissipation of energy; diatomite, on the other hand, is in the 1–100 µm range. Resonance-based sound absorption through its siliceous structure containing natural micro-voids. It supports the mechanism. Fly ash increases matrix density and late age While improving its strength, cellulose fibers contribute to foam stability and microcrack control. This provides a contribution. The way in which the contribution rates specific to the layers are structured... Thanks to this, the mechanical strength and acoustic performance of the composite are simultaneously improved. It is being developed. In the resulting three-layered composite system, the substrate is structural. It undertakes the load-bearing function, while the top layer provides enhanced acoustic absorption performance. And the middle layer functions as a gradual transition between these two regions. Thus, the structure The structural requirements of the element and the acoustic comfort requirements are combined in a single structure. It can meet the needs. The developed composite system includes precast panels, interior partition walls, and sound insulation. absorbent surface coating, industrial noise control panel and lightweight structural component. It is suitable for use in various applications.

Claims

1. Functionally graded with optimized mechanical and acoustic properties. It is a foamed concrete composite, characterized by its sequential structure. - binder in the range of 55–70% by weight of the dry mix, total mix Foam in the range of 10–20% of volume, binder phase 10–25% fly ash in the range of 5–15%, diatomite in the binder phase and Cellulose fiber in the range of 0.10–0.50% of the total dry mix weight. containing substructure layer, - total pore structure with an average diameter ranging from 0.5–2.0 mm. Foam content should be between 20–35% of the mix volume and the total aggregate volume. It should contain a mid-transition layer with rubber aggregate in the range of 10–25%, - foam in the range of 35–55% of the total mix volume, total aggregate Rubber aggregate in the range of 25–40% by volume, binder phase 10–20% diatomite in the range of 0.15–0.60% of the total dry mix weight. containing cellulose fibers in the range of 0.1–1.0 mm and an average pore diameter. acoustic active with a finely dispersed open pore structure remaining within the range. The region is characterized by containing an upper acoustic layer. 6