Unburned hollow aggregate, preparation method thereof, and light-weight concrete wallboard and preparation method thereof

Abstract

The application belongs to the technical field of building materials, and provides a baking-free hollow aggregate, a preparation method thereof, and a lightweight concrete wallboard and a preparation method thereof. The waste foam particles shrink in volume when heated, forming cavities inside the aggregate. After the waste foam particles melt, a dense resin film is formed on the surface of the cavities, which can form a relatively closed air layer in the lightweight concrete wallboard, achieving better sound insulation and thermal insulation effects. The chopped fibers can make the construction waste, mineral powder and fly ash better combined with the waste foam particles, making the whole more compact, and thus improving the strength and crack resistance of the baking-free hollow aggregate. At the same time, the chopped fibers can form burr-like protrusions on the surface of the baking-free hollow aggregate, which can inhibit the baking-free hollow aggregate from floating up during the preparation of the lightweight concrete wallboard, so that the baking-free hollow aggregate is uniformly distributed in the lightweight concrete wallboard. The baking-free hollow aggregate has a hollow structure, so that the lightweight concrete wallboard has a low surface density.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of building materials, and particularly relates to a sintering-free hollow aggregate, a preparation method thereof, and a lightweight concrete wallboard and a preparation method thereof. BACKGROUND

[0002] With the advancement of urbanization process in China and the rapid updating and construction of urban infrastructure, a large amount of engineering slag is produced. Due to the lack of corresponding resource disposal technology, only a small part of the engineering slag is disposed of. The engineering slag occupies and pollutes the land, and a large amount of dust and harmful gas is generated during the stacking and transportation of the engineering slag, which affects the air quality, destroys the city appearance, and deteriorates the urban environmental sanitation. The leachate generated by the stacked engineering slag enters the river with rainwater, which seriously pollutes the surrounding surface water and groundwater. Moreover, most cities have not formulated effective schemes for the stacking of engineering slag, thereby causing different degrees of safety hazards.

[0003] At present, the disposal method of the engineering slag at the present stage is used for site backfill, hill making and road foundation filling, and the demand is small. In some cities, the engineering slag is used as a raw material for sintered bricks, but with the tightening of environmental protection policies, more and more cities have issued bans on burning, and the disposal of engineering slag is facing great challenges.

[0004] The lightweight concrete wallboard has many advantages such as green environmental protection, shock resistance, sound insulation, and heat preservation. However, the production of the main raw material of the lightweight concrete wallboard, i.e., lightweight aggregate, still needs to be sintered, which consumes a large amount of energy and makes it difficult to achieve mass production in cities where burning is prohibited. SUMMARY

[0005] Therefore, the present application aims to provide a sintering-free hollow aggregate, a preparation method thereof, and a lightweight concrete wallboard and a preparation method thereof. The sintering-free hollow aggregate provided by the present application uses engineering slag and waste foam particles, thereby reducing the environmental pressure.

[0006] In order to achieve the above-mentioned application purposes, the present application provides the following technical solutions.

[0007] The present application provides a sintering-free hollow aggregate, which comprises the following preparation raw materials:

[0008] Engineering slag, waste foam particles, water glass, mineral powder, fly ash, cement, short-cut fiber, sodium hydroxide, and water.

[0009] Preferably, the preparation raw materials comprise the following weight fractions:

[0010] Engineering slag 550-650 parts, waste foam particles 8-12 parts, water glass 65-105 parts, mineral powder 140-175 parts, fly ash 170-210 parts, cement 30-50 parts, chopped fiber 0.5-1.5 parts, sodium hydroxide 30-50 parts, water 240-270 parts.

[0011] Preferably, the particle size of the engineering slag is ≤0.15mm; the material of the waste foam particles is polystyrene, and the particle size is 2-15mm; the modulus of the water glass is 2.8-3.2; the grade of the mineral powder is S95 grade and above; the grade of the fly ash is secondary and above; the cement is portland cement; the chopped fiber is chopped alkali-resistant glass fiber and / or chopped basalt fiber, the length is 3-6mm, the diameter is 30-35μm, the tensile strength is 1800-2000MPa, and the elastic modulus is 33-35GPa; the purity of the sodium hydroxide is ≥99%; and the water is tap water.

[0012] Preferably, the particle size of the non-burning hollow aggregate is 3-20m, the bulk density is 600-700kg / m 3 , the cylinder compressive strength is 3-4MPa, the aggregate is hollow cavity structure, and the size of the hollow cavity structure is 2-15mm.

[0013] The application also provides a preparation method of the non-burning hollow aggregate.

[0014] Mixing sodium hydroxide, water glass and water to obtain an alkaline solution;

[0015] Mixing engineering slag, mineral powder, fly ash and cement to obtain a mixed powder;

[0016] In the alkaline solution, the waste foam particles are sequentially infiltrated and filtered to obtain infiltrated waste foam particles and filtrate, respectively;

[0017] Placing the infiltrated waste foam particles in a disc granulator, and uniformly screening part of the chopped fiber into the disc granulator to obtain fiber-wrapped waste foam particles;

[0018] Filling the filtrate into a spraying device, and under the condition that the spraying device sprays the filtrate, screening the mixed powder and the remaining chopped fiber into the disc granulator to obtain a shaped particle;

[0019] Curing the shaped particle to obtain the non-burning hollow aggregate.

[0020] Preferably, the curing includes sequentially performing first curing, second curing and third curing;

[0021] The first curing is room temperature film curing, and the time of the room temperature film curing is 7 days.

[0022] The temperature of the second curing is 100 DEG C, and the time is 5-8h;

[0023] The temperature of the third curing is 150-200 DEG C, and the time is 5-30min;

[0024] During the third curing, the formed particles are turned over every 30-50s.

[0025] The application further provides a lightweight concrete wallboard prepared from the following raw materials:

[0026] unburned hollow aggregate, expanded perlite, cement, mineral powder, water reducing agent and water;

[0027] The unburned hollow aggregate is the unburned hollow aggregate in the above technical solution or the unburned hollow aggregate prepared by the preparation method in the above technical solution.

[0028] Preferably, the preparation raw materials include the following weight fractions:

[0029] unburned hollow aggregate 460-520 parts, expanded perlite 40-60 parts, cement 210-270 parts, mineral powder 140-180 parts, water reducing agent 5-8 parts and water 160-180 parts.

[0030] Preferably, the expanded perlite has a particle size of 1-3mm and a bulk density of 90-150kg / m 3 .

[0031] The application further provides a preparation method of the lightweight concrete wallboard in the above technical solution, including the following steps:

[0032] mixing unburned hollow aggregate, expanded perlite, cement and mineral powder to obtain a mixture;

[0033] mixing water reducing agent, water and the mixture to obtain lightweight concrete;

[0034] sequentially forming and curing the lightweight concrete to obtain the lightweight concrete wallboard.

[0035] The application provides a non-burning hollow aggregate, which comprises the following preparation raw materials: engineering slag, waste foam particles, water glass, mineral powder, fly ash, cement, chopped fibers, sodium hydroxide and water. The non-burning hollow aggregate of the application uses a large amount of engineering slag and waste foam particles, thereby providing a new resource utilization way for the resource utilization of engineering slag and waste foam particles and reducing the environmental protection pressure. The waste foam particles shrink in volume when heated to form cavities in the aggregate, and a layer of dense resin film is formed on the surface of the cavities after the waste foam particles are melted, which can form a relatively closed air layer in the light-weight concrete wallboard, thereby achieving better sound insulation and heat preservation effects. The chopped fibers make the engineering slag and the hydration products of geopolymer cementitious materials (including mineral powder and fly ash) better combined with the waste foam particles, so that the whole is more compact, thereby improving the strength and crack resistance of the non-burning hollow aggregate; at the same time, the chopped fibers can form burr-like protrusions on the surface of the non-burning hollow aggregate, which can inhibit the upward floating of the non-burning hollow aggregate during the preparation of the wallboard, so that the non-burning hollow aggregate is uniformly distributed in the light-weight concrete wallboard. The non-burning hollow aggregate of the application has high strength and good quality.

[0036] The application further provides a preparation method of the non-burning hollow aggregate, which comprises the following steps: mixing sodium hydroxide, water glass and water to obtain an alkaline solution; mixing engineering slag, mineral powder, fly ash and cement to obtain mixed powder; sequentially immersing and filtering waste foam particles in the alkaline solution to obtain immersed waste foam particles and filtrate, respectively; placing the immersed waste foam particles in a disc granulator, uniformly screening part of the chopped fibers into the disc granulator to obtain fiber-wrapped waste foam particles; loading the filtrate into a spraying device, screening the mixed powder and the remaining chopped fibers into the disc granulator under the condition that the spraying device sprays the filtrate to obtain shaped particles; and curing the shaped particles to obtain the non-burning hollow aggregate. The preparation method provided by the application does not need high-temperature sintering, and can realize batch production in a "non-burning city".

[0037] Further, the curing comprises sequentially performing first curing, second curing and third curing; the first curing is room temperature film coating curing, and the time of the room temperature film coating curing is 7 days; the temperature of the second curing is 100 DEG C, and the time is 5-8h; the temperature of the third curing is 150-200 DEG C, and the time is 5-30min; and the shaped particles are turned over every 30-50s during the third curing. The curing with gradually increasing temperature fully stimulates the strength of the active materials in the preparation raw materials, so that the obtained non-burning hollow aggregate has higher strength and a more compact outer surface, thereby improving the durability of the non-burning hollow aggregate.

[0038] The application further provides a lightweight concrete wallboard, which comprises the following preparation raw materials: the non-burned hollow aggregate, expanded perlite, cement, mineral powder, water reducing agent and water; the non-burned hollow aggregate is the non-burned hollow aggregate in the above technical solution or the non-burned hollow aggregate prepared by the preparation method in the above technical solution. The non-burned hollow aggregate is a hollow structure and has a clean air layer inside, and the existence of the clean air layer can greatly reduce the bulk density of the non-burned hollow aggregate, so that the lightweight concrete wallboard has a lower surface density.

[0039] The application further provides a preparation method of the lightweight concrete wallboard in the above technical solution, which comprises the following steps: mixing the non-burned hollow aggregate, expanded perlite, cement and mineral powder to obtain a mixture; mixing the water reducing agent, water and the mixture to obtain lightweight concrete; and sequentially performing molding and curing on the lightweight concrete to obtain the lightweight concrete wallboard. The preparation method of the lightweight concrete wallboard provided by the application has a simple production process.

[0040] The data of the examples show that the bulk density of the non-burned hollow aggregate provided by the application is 603-688 kg / m 3 , and the cylinder compressive strength is 3.4-3.9 MPa; the surface density of the lightweight concrete wallboard provided by the application is 108-118 kg / m 2 , the sound insulation performance is 45-51 db, and the thermal conductivity is 0.29-0.44 W / (m 2 ·K). DETAILED DESCRIPTION

[0041] The application provides a non-burned hollow aggregate, which comprises the following preparation raw materials:

[0042] Engineering slag, waste foam particles, water glass, mineral powder, fly ash, cement, chopped fibers, sodium hydroxide and water.

[0043] In the application, the raw materials used in the application are preferably commercially available products, unless otherwise specified.

[0044] The non-burned hollow aggregate provided by the application comprises the preparation raw material engineering slag, and the engineering slag is preferably engineering produced spoil, and the main components are silicon oxide, aluminum oxide and iron oxide. In the application, the particle size of the engineering slag is preferably ≤0.15 mm. In the application, the weight fraction of the engineering slag is preferably 550-650 parts, further preferably 575-625 parts, and more preferably 600 parts.

[0045] The non-burning hollow aggregate provided by the application comprises waste foam particles as raw materials, and the material of the waste foam particles is preferably polystyrene. In the application, the particle size of the waste foam particles is preferably 2-15 mm. In the application, the weight fraction of the waste foam particles is preferably 8-12 parts, further preferably 9-11 parts, and more preferably 10 parts, based on the weight fraction of the engineering sludge.

[0046] The non-burning hollow aggregate provided by the application comprises water glass as raw materials, and the modulus of the water glass is preferably 2.8-3.2. In the application, the weight fraction of the water glass is preferably 65-105 parts, further preferably 75-95 parts, and more preferably 80 parts, based on the weight fraction of the engineering sludge.

[0047] The non-burning hollow aggregate provided by the application comprises mineral powder as raw materials, and the grade of the mineral powder is preferably S95 or above, and further preferably S95-S105. In the application, the weight fraction of the mineral powder is preferably 140-175 parts, further preferably 150-160 parts, and more preferably 155 parts, based on the weight fraction of the engineering sludge.

[0048] The non-burning hollow aggregate provided by the application comprises fly ash as raw materials, and the grade of the fly ash is preferably secondary or above, and further preferably secondary. In the application, the weight fraction of the fly ash is preferably 170-210 parts, further preferably 180-200 parts, and more preferably 190 parts, based on the weight fraction of the engineering sludge.

[0049] The non-burning hollow aggregate provided by the application comprises cement as raw materials, and the cement is preferably Portland cement, and the strength of the Portland cement is preferably 42.5. In the application, the weight fraction of the cement is preferably 30-50 parts, further preferably 35-45 parts, and more preferably 40 parts, based on the weight fraction of the engineering sludge.

[0050] The non-burning hollow aggregate provided by the application comprises short-cut fibers as raw materials, and the short-cut fibers are preferably short-cut alkali-resistant glass fibers and / or short-cut basalt fibers; the length of the short-cut fibers is preferably 3-6 mm, the diameter is preferably 30-35 μm, the tensile strength is preferably 1800-2000 MPa, and the elastic modulus is preferably 33-35 GPa. In the application, the weight fraction of the short-cut fibers is preferably 0.5-1.5 parts, further preferably 1 part, based on the weight fraction of the engineering sludge.

[0051] The non-burning hollow aggregate provided by the application comprises a preparation raw material of sodium hydroxide, and the purity of the sodium hydroxide is preferably greater than or equal to 99%, and the sodium hydroxide is preferably industrial flaky sodium hydroxide. In the application, the weight fraction of the sodium hydroxide is preferably 30-50 parts, further preferably 35-45 parts, and more preferably 40 parts, based on the weight fraction of the engineering slag.

[0052] The non-burning hollow aggregate provided by the application comprises a preparation raw material of water, and the water is preferably tap water. In the application, the weight fraction of the water is preferably 240-270 parts, further preferably 250-260 parts, and more preferably 255 parts, based on the weight fraction of the engineering slag.

[0053] In the application, the particle size of the non-burning hollow aggregate is preferably 3-20 mm, the bulk density is preferably 600-700 kg / m 3 , the cylinder compressive strength is preferably 3-4 MPa, the aggregate is preferably of a hollow structure, and the size of the hollow structure is preferably 2-15 mm.

[0054] The application further provides a preparation method of the non-burning hollow aggregate.

[0055] The sodium hydroxide, water glass and water are mixed to obtain an alkaline solution.

[0056] The engineering slag, mineral powder, fly ash and cement are mixed to obtain a mixed powder.

[0057] The waste foam particles are sequentially infiltrated and filtered in the alkaline solution to obtain infiltrated waste foam particles and filtrate, respectively.

[0058] The infiltrated waste foam particles are placed in a disc granulator, and part of the short-cut fibers are uniformly sieved into the disc granulator to obtain fiber-wrapped waste foam particles.

[0059] The filtrate is loaded into a spraying device, and the mixed powder and the remaining short-cut fibers are sieved into the disc granulator under the condition that the spraying device sprays the filtrate to obtain shaped particles.

[0060] The shaped particles are cured to obtain the non-burning hollow aggregate.

[0061] The sodium hydroxide, water glass and water are mixed to obtain an alkaline solution. In the application, the sodium hydroxide, water glass and water are mixed as follows: the sodium hydroxide and water are mixed to obtain a sodium hydroxide aqueous solution; and the sodium hydroxide aqueous solution and water glass are mixed at room temperature to obtain an alkaline solution. In the application, the mixing is preferably carried out under stirring.

[0062] The engineering slag, the mineral powder, the fly ash and the cement are mixed to obtain mixed powder in the present application.

[0063] After obtaining the alkaline solution, the waste foam particles are sequentially infiltrated and filtered in the alkaline solution to obtain infiltrated waste foam particles and filtrate respectively.

[0064] In the present application, the temperature of the infiltration is preferably 20-30℃, and further preferably 20-25℃, and the time is preferably 2-3min. The filtration is not specifically limited in the present application, as long as the infiltrated waste foam particles and the liquid can be separated.

[0065] After obtaining the infiltrated waste foam particles, the infiltrated waste foam particles are placed in a disc granulator, and part of the short-cut fibers are uniformly screened into the disc granulator to obtain fiber-wrapped waste foam particles.

[0066] In specific embodiments of the present application, the model of the disc granulator is preferably The rotation speed is preferably 19-25r / min, and about 0.5m 3 .

[0067] In the present application, the part of the short-cut fibers is preferably uniformly screened into the disc granulator through a standard square hole screen, and the pore size of the standard square hole screen is preferably 1.18-2.36mm. In the present application, the mass of the part of the short-cut fibers is 10-20% of the total mass of the short-cut fibers.

[0068] After obtaining the filtrate, the filtrate is loaded into a spraying device, and under the condition that the filtrate is sprayed by the spraying device, the mixed powder and the remaining short-cut fibers are screened into the disc granulator to obtain shaped particles.

[0069] In the present application, the flow rate of the spraying is preferably 1-1.2kg / min. In the present application, the mixed powder and the remaining short-cut fibers are preferably screened into the disc granulator in batches, and the number of batches is preferably 45-50 batches.

[0070] After obtaining the shaped particles, the shaped particles are cured to obtain the non-burned hollow aggregate.

[0071] In the present application, the curing preferably comprises sequentially performing a first curing, a second curing and a third curing. In the present application, the first curing is preferably room temperature film curing, and the time of the room temperature film curing is preferably 7 days. In the present application, the temperature of the second curing is preferably 100 DEG C, and the time of the second curing is preferably 5-8 hours. In the present application, the temperature of the third curing is preferably 150-200 DEG C, and the time of the third curing is preferably 5-30 minutes; during the third curing, the formed particles are preferably turned over every 30-50 seconds.

[0072] The present application further provides a lightweight concrete wallboard comprising the following preparation raw materials:

[0073] The non-burned hollow aggregate is the non-burned hollow aggregate described in the above technical solution or the non-burned hollow aggregate prepared by the preparation method described in the above technical solution.

[0074] The non-burned hollow aggregate is the non-burned hollow aggregate described in the above technical solution or the non-burned hollow aggregate prepared by the preparation method described in the above technical solution.

[0075] The lightweight concrete wallboard provided by the present application comprises the non-burned hollow aggregate as the preparation raw material, and the non-burned hollow aggregate is the non-burned hollow aggregate described in the above technical solution or the non-burned hollow aggregate prepared by the preparation method described in the above technical solution. In the present application, the weight fraction of the non-burned hollow aggregate is preferably 460-520 parts, further preferably 470-510 parts, and more preferably 490-500 parts.

[0076] The lightweight concrete wallboard provided by the present application comprises the expanded perlite as the preparation raw material, and the particle size of the expanded perlite is preferably 1-3 mm, and the bulk density is preferably 90-150 kg / m 3 . In the present application, the weight fraction of the expanded perlite is preferably 40-60 parts, further preferably 45-55 parts, and more preferably 50 parts, based on the weight fraction of the non-burned hollow aggregate.

[0077] The lightweight concrete wallboard provided by the present application comprises the cement as the preparation raw material, and the cement is preferably Portland cement, and the strength of the Portland cement is preferably 42.5. In the present application, the weight fraction of the cement is preferably 210-270 parts, further preferably 220-260 parts, and more preferably 230-250 parts, based on the weight fraction of the non-burned hollow aggregate.

[0078] The lightweight concrete wallboard provided by the present application comprises the mineral powder as the preparation raw material, and the grade of the mineral powder is preferably S95 grade or above. In the present application, the weight fraction of the mineral powder is preferably 140-180 parts, further preferably 160-170 parts, based on the weight fraction of the non-burned hollow aggregate.

[0079] The lightweight concrete wallboard provided by the present invention includes a water reducer as a raw material; the water reducer is preferably a polycarboxylate water reducer. In the present invention, the water reducer is preferably present in an amount of 5 to 8 parts by weight, more preferably 6 to 7 parts by weight, based on the weight of the unfired hollow aggregate.

[0080] The lightweight concrete wallboard provided by the present invention includes raw water for preparation; the water is preferably tap water. In the present invention, the weight of the water is preferably 160 to 180 parts, more preferably 165 to 175 parts, and even more preferably 170 parts, based on the weight of the unfired hollow aggregate.

[0081] The present invention also provides a method for preparing the lightweight concrete wallboard described in the above technical solution, comprising the following steps:

[0082] Mixing unburned hollow aggregate, expanded perlite, cement and mineral powder to obtain a mixture;

[0083] Mixing a water reducing agent, water and a mixture to obtain lightweight concrete;

[0084] The lightweight concrete is molded and cured in sequence to obtain the lightweight concrete wallboard.

[0085] The invention mixes unburned hollow aggregate, expanded perlite, cement and mineral powder to obtain a mixture.

[0086] In the present invention, the time for mixing the unburned hollow aggregate, expanded perlite, cement and mineral powder is preferably 30 to 60 seconds. In the present invention, the mixing is preferably carried out in a concrete mixer.

[0087] After obtaining the mixture, the present invention mixes a water reducing agent, water and the mixture to obtain lightweight concrete.

[0088] In the present invention, the mixing time of the water reducing agent, water and mixed material is preferably 120 to 180 seconds. In the present invention, the mixing is preferably carried out in a concrete mixer.

[0089] After obtaining the lightweight concrete, the present invention sequentially shapes and cures the lightweight concrete to obtain the lightweight concrete wallboard.

[0090] In the present invention, the molding is preferably performed in a mold. In the present invention, the curing is preferably standard curing, wherein the temperature of the standard curing is preferably 20±2° C., the humidity is preferably ≥95%, and the curing time is preferably 28 days.

[0091] The unburned hollow aggregate and its preparation method and the lightweight concrete wallboard and its preparation method provided by the present invention are described in detail below with reference to the embodiments, but they should not be understood as limiting the scope of protection of the present invention.

[0092] Example 1

[0093] A preparation raw material of the baking-free hollow aggregate comprises the following components in parts by weight:

[0094] 550 parts of engineering slag (engineering output spoil, particle size ≤ 0.15 mm), 12 parts of waste foam particles (obtained by crushing waste foam board, particle size 2-15 mm, main component polystyrene), 105 parts of water glass (modulus 3.2), 175 parts of mineral powder (grade S95), 210 parts of fly ash (grade two), 30 parts of cement (PO42.5R cement), 1.5 parts of chopped fiber (chopped alkali-resistant glass fiber, length 3 mm, diameter 30 μm, tensile strength 1810 MPa, elastic modulus 33 GPa), 50 parts of sodium hydroxide (industrial grade flaky sodium hydroxide), and 240 parts of water (tap water).

[0095] The preparation method comprises the following steps:

[0096] Dissolve sodium hydroxide in water, and after cooling to room temperature, add water glass, fully stir and dissolve to obtain an alkaline solution.

[0097] Mix the engineering slag, mineral powder, fly ash and cement with a V-type mixer to obtain mixed powder.

[0098] Put the waste foam particles into the alkaline solution and soak at 20°C for 2 min, take out, and obtain soaked waste foam particles and filtrate, respectively.

[0099] Put the soaked waste foam particles into a disc granulator, and at the same time, use a standard square hole screen (pore size 2.36) to uniformly screen 0.3 parts of chopped fiber into the disc granulator, so that the surface of the soaked waste foam particles uniformly adheres to the chopped fiber, and obtain fiber-coated waste foam particles.

[0100] Fill the filtrate into a spraying device, under the condition that the spraying device sprays the filtrate (the flow rate of spraying is 1-1.2 kg / min), uniformly distribute the mixed powder and the remaining chopped fiber into the disc granulator in 45 batches, and ensure that the mixed powder, the remaining chopped fiber and the fiber-coated waste foam particles are fully adhered together, screen out particles of 3-20 mm with a standard square hole screen, and obtain shaped particles.

[0101] Cover film curing of the shaped particles at room temperature for 7 days, place in a 100°C environment for second curing for 8 h, and then heat to 200°C for third curing for 5 min, and turn over the shaped particles every 30 s during the third curing, to obtain baking-free hollow aggregate.

[0102] A lightweight concrete wallboard comprises the following components in parts by weight:

[0103] The lightweight concrete wallboard comprises the following components in kilograms:

[0104] The non-fired hollow aggregate obtained in Example 1 is 460 parts, expanded perlite (the particle size of the expanded perlite is 1-3 mm, and the bulk density is 120 kg / m 3 ) 40 parts, cement (PO42.5R cement) 210 parts, mineral powder (grade S95) 140 parts, water reducing agent (polycarboxylic acid water reducing agent) 5 parts, and water (tap water) 160 parts.

[0105] The preparation method comprises the following steps:

[0106] The non-fired hollow aggregate, expanded perlite, cement, and mineral powder are placed in a concrete mixer and stirred for 30 s to obtain a mixture.

[0107] The polycarboxylic acid water reducing agent and water are mixed and then added to the concrete mixer and stirred for 180 s to obtain lightweight concrete.

[0108] The obtained lightweight concrete is poured into a mold, vibrated and formed, and standard cured for 28 d according to the relevant standards for reinforcing lightweight concrete wallboards to obtain a lightweight concrete wallboard with a specification of 2400 mm*500 mm*90 mm.

[0109] Example 2

[0110] A preparation raw material of a non-fired hollow aggregate comprises the following components in parts by weight:

[0111] The engineering spoil (engineering spoil, particle size ≤0.15 mm) is 650 parts, the waste foam particles (obtained by crushing waste foam boards, particle size is 2-15 mm, and the main component of the waste foam board is polystyrene) are 8 parts, the water glass (modulus is 2.8) is 65 parts, the mineral powder (grade S105) is 140 parts, the fly ash (grade two) is 170 parts, the cement (PO42.5R cement) is 50 parts, the chopped fiber (basalt fiber, length is 6 mm, diameter is 35 μm, tensile strength is 1989 MPa, and elastic modulus is 35 GPa) is 0.5 parts, the sodium hydroxide (industrial grade flaky sodium hydroxide) is 30 parts, and the water (tap water) is 270 parts.

[0112] The preparation method comprises the following steps:

[0113] The sodium hydroxide is dissolved in water, and after being cooled to room temperature, the water glass is added, and after being fully stirred and dissolved, an alkaline solution is obtained.

[0114] The engineering spoil, mineral powder, fly ash, and cement are uniformly mixed by using a V-type mixer to obtain a mixed powder.

[0115] The waste foam particles are put into the alkaline solution for 3 min at 25℃, taken out, and waste foam particles after soaking and filtrate are obtained respectively.

[0116] The waste foam particles after soaking are placed in a disc granulator, and 0.1 parts of short fibers are sieved into the disc granulator by using a standard square hole screen (pore size is 1.18) to make the waste foam particles after soaking uniformly adhere to the surface of the short fibers, and fiber-wrapped waste foam particles are obtained.

[0117] The filtrate is filled into a spraying device, and the mixed powder and the remaining short fibers are uniformly distributed into the disc granulator in 49 batches under the condition that the filtrate is sprayed by the spraying device (the flow rate of spraying is 1-1.2 kg / min) to ensure that the mixed powder, the remaining short fibers and the fiber-wrapped waste foam particles are fully adhered together, and the particles of 3-20 mm are sieved out by using a standard square hole screen to obtain formed particles.

[0118] The formed particles are coated and maintained at room temperature for 7 days, placed in an environment of 100℃ for the second curing for 5 h, and then heated to 150℃ for the third curing for 30 min, and the formed particles are turned over every 40 s during the third curing to obtain the non-fired hollow aggregate.

[0119] A lightweight concrete wallboard comprises the following preparation raw materials in parts by weight:

[0120] The non-fired hollow aggregate obtained in Example 2 is 520 parts, expanded perlite (particle size is 1-3 mm, bulk density is 90 kg / m 3 ) 60 parts, cement (PO42.5R cement) 270 parts, mineral powder (grade is S95 grade) 180 parts, water reducing agent (polycarboxylic acid water reducing agent) 8 parts, and water (tap water) 180 parts.

[0121] The preparation method comprises the following steps:

[0122] The non-fired hollow aggregate, the expanded perlite, the cement and the mineral powder are placed in a concrete mixer and stirred for 60 s to obtain a mixture.

[0123] The polycarboxylic acid water reducing agent and the water are mixed and then added to the concrete mixer and stirred for 120 s to obtain the lightweight concrete.

[0124] The obtained lightweight concrete is poured into a mold, vibrated and formed, and standard cured for 28 days according to the related standards of the lightweight concrete wallboard to obtain a lightweight concrete wallboard with a specification of 2400 mm*500 mm*90 mm.

[0125] Example 3

[0126] A preparation raw material of a non-fired hollow aggregate comprises the following components in parts by weight:

[0127] 600 parts of engineering slag (engineering output spoil, particle size ≤ 0.15 mm), 10 parts of waste foam particles (obtained by crushing waste foam board, particle size 2-15 mm, main component of waste foam board is polystyrene), 85 parts of water glass (modulus 3.0), 160 parts of mineral powder (grade S95), 190 parts of fly ash (grade two), 40 parts of cement (PO42.5R cement), 1 part of chopped fiber (chopped alkali-resistant glass fiber, length 4 mm, diameter 30 μm, tensile strength 1902 MPa, elastic modulus 34 GPa), 40 parts of sodium hydroxide (industrial grade flaky sodium hydroxide), and 255 parts of water (tap water) are used as raw materials.

[0128] The preparation method comprises the following steps:

[0129] Sodium hydroxide is dissolved in water, and after cooling to room temperature, water glass is added. After sufficient stirring and dissolution, an alkaline solution is obtained.

[0130] The engineering slag, mineral powder, fly ash and cement are mixed uniformly with a V-type mixer to obtain mixed powder.

[0131] The soaked waste foam particles are placed in a disc granulator in batches, and 0.15 parts by weight of chopped fiber is uniformly sieved into the disc granulator using a standard square hole sieve (pore size 2.36 mm) to uniformly adhere chopped fiber to the surface of the soaked waste foam particles, thereby obtaining fiber-coated waste foam particles.

[0132] The filtrate is loaded into a spraying device, and under the condition that the filtrate is sprayed (flow rate 1-1.2 kg / min) by the spraying device, the mixed powder and the remaining chopped fiber are uniformly distributed to the disc granulator in 47 batches to ensure that the mixed powder, the remaining chopped fiber and the fiber-coated waste foam particles are fully adhered together. The particles of 3-20 mm are sieved out with a standard square hole sieve to obtain shaped particles.

[0133] The shaped particles are cured at room temperature for 7 days, placed in a 100℃ environment for the second curing for 6 h, and then heated to 175℃ for the third curing for 15 min. The shaped particles are turned over every 50 s during the third curing to obtain the non-fired hollow aggregate.

[0134] A lightweight concrete wallboard comprises the following raw materials by weight:

[0135] 490 parts of non-fired hollow aggregate obtained in Example 3, 50 parts of expanded perlite (particle size 1-3 mm, bulk density 90 kg / m 3 ), 240 parts of cement (PO42.5R cement), 160 parts of mineral powder (grade S95), 7 parts of water reducing agent (polycarboxylic acid water reducing agent), and 170 parts of water (tap water) are used as raw materials.

[0136] The preparation method comprises the following steps:

[0137] The non-burned hollow aggregate, expanded perlite, cement and mineral powder are weighed according to the proportion, and then are placed in a concrete mixer and stirred for 45s to obtain a mixture.

[0138] The polycarboxylic acid water reducing agent and water are mixed, and then are added into the concrete mixer and stirred for 150s to obtain the lightweight concrete.

[0139] The obtained lightweight concrete is poured into a mold according to the related standard of the lightweight concrete wallboard, and is vibrated and formed, and is standard cured for 28 days to obtain a lightweight concrete wallboard with a specification of 2400mm*500mm*90mm.

[0140] The bulk density and cylinder compressive strength of the non-burned hollow aggregate obtained in Examples 1-3 are determined by GBT17431.1-2010 'Lightweight Aggregate and Its Test Methods', and the wallboard surface density, sound insulation performance and thermal conductivity of the lightweight concrete wallboard obtained in Examples 1-3 are determined by JC / T 2214-2014 'Steel Reinforced Lightweight Concrete Wallboard', and the results are shown in Table 1.

[0141] Table 1 Test results

[0142]

[0143] As shown in Table 1, the cylinder compressive strength of the non-burned hollow aggregate prepared under the non-burning condition can meet the requirements of the national standard GBT17431.1-2010 'Lightweight Aggregate and Its Test Methods' on the cylinder compressive strength of artificial lightweight aggregate, the surface density of the 90mm-thick lightweight concrete wallboard prepared by using the non-burned hollow aggregate meets the requirements of JC / T 2214-2014 'Steel Reinforced Lightweight Concrete Wallboard', the sound insulation performance meets the requirements of the 100mm-thick and 120mm-thick lightweight concrete wallboard, and the thermal conductivity far exceeds the requirement of ≤2.0W / (m 2 ·K).

[0144] The above only describes the preferred embodiments of the present application, and it should be noted that, for those skilled in the art, some improvements and refinements can be made without departing from the principles of the present application, and these improvements and refinements should also be considered as the protection scope of the present application.

Claims

1. A non-fired hollow aggregate, characterized in that, The preparation raw materials include the following parts by weight: 550-650 parts of engineering slag, 8-12 parts of waste foam particles, 65-105 parts of water glass, 140-175 parts of mineral powder, 170-210 parts of fly ash, 30-50 parts of cement, 0.5-1.5 parts of chopped fiber, 30-50 parts of sodium hydroxide, and 240-270 parts of water; The particle size of the engineering slag is ≤0.15 mm; the material of the waste foam particles is polystyrene, and the particle size is 2-15 mm; The preparation method of the non-burning hollow aggregate comprises the following steps: Mixing sodium hydroxide, water glass and water to obtain an alkaline solution; Mixing engineering slag, mineral powder, fly ash and cement to obtain mixed powder; The waste foam particles are sequentially immersed and filtered in the alkaline solution to obtain immersed waste foam particles and filtrate, respectively; The immersed waste foam particles are placed in a disc granulator, and part of the chopped fiber is sieved into the disc granulator to obtain fiber-wrapped waste foam particles; The filtrate is loaded into a spraying device, and under the condition that the spraying device sprays the filtrate, the mixed powder and the remaining chopped fiber are sieved into the disc granulator to obtain shaped particles; The shaped particles are cured to obtain the non-burning hollow aggregate; The curing comprises sequentially performing first curing, second curing and third curing; The first curing is room temperature film curing, and the time of the room temperature film curing is 7 days; The temperature of the second curing is 100℃, and the time is 5-8h; The temperature of the third curing is 150-200℃, and the time is 5-30min; During the third curing, the shaped particles are turned over every 30-50s.

2. The non-fired hollow aggregate according to claim 1, characterized in that The particle size of the engineering slag is ≤0.15 mm; the material of the waste foam particles is polystyrene, and the particle size is 2-15 mm; the modulus of the water glass is 2.8-3.2; the grade of the mineral powder is S95 and above; the grade of the fly ash is secondary and above; the cement is portland cement; the chopped fiber is chopped alkali-resistant glass fiber and / or chopped basalt fiber, with a length of 3-6mm, a diameter of 30-35μm, a tensile strength of 1800-2000MPa, and an elastic modulus of 33-35GPa; the purity of the sodium hydroxide is ≥99%; and the water is tap water.

3. The non-fired hollow aggregate according to claim 1, characterized in that, The particle size of the non-burned hollow aggregate is 3-20 mm, and the volume weight is 600-700 kg / m 3 The barrel pressure strength is 3-4 MPa, the aggregate is hollow structure, and the size of the hollow structure is 2-15 mm.

4. Process for the production of a non-fired hollow aggregate according to any one of claims 1 to 3, characterized in that The preparation method of the non-burning hollow aggregate comprises the following steps: Mixing sodium hydroxide, water glass and water to obtain an alkaline solution; Mixing engineering slag, mineral powder, fly ash and cement to obtain mixed powder; The waste foam particles are sequentially immersed and filtered in the alkaline solution to obtain immersed waste foam particles and filtrate, respectively; The immersed waste foam particles are placed in a disc granulator, and part of the chopped fiber is sieved into the disc granulator to obtain fiber-wrapped waste foam particles; The filtrate is loaded into a spraying device, and under the condition that the spraying device sprays the filtrate, the mixed powder and the remaining chopped fiber are sieved into the disc granulator to obtain shaped particles; The shaped particles are cured to obtain the non-burning hollow aggregate; The curing comprises sequentially performing first curing, second curing and third curing; The first curing is room temperature film curing, and the time of the room temperature film curing is 7 days; The temperature of the second curing is 100 DEG C, and the time is 5-8 h; The temperature of the third curing is 150-200 DEG C, and the time is 5-30 min; During the third curing, the formed particles are turned over every 30-50 s.

5. A lightweight concrete wall panel characterised in that, The preparation raw materials include: unburned hollow aggregate, expanded perlite, cement, mineral powder, water reducing agent and water; The unburned hollow aggregate is the unburned hollow aggregate according to any one of claims 1-3 or the unburned hollow aggregate prepared by the preparation method of claim 4.

6. A lightweight concrete wall panel according to claim 5, characterised in that, The preparation raw materials include the following components in parts by weight: unburned hollow aggregate 460-520 parts, expanded perlite 40-60 parts, cement 210-270 parts, mineral powder 140-180 parts, water reducing agent 5-8 parts, and water 160-180 parts.

7. A lightweight concrete wall panel according to claim 5 or 6, characterised in that, The particle size of the expanded perlite is 1-3 mm, and the bulk density is 90-150 kg / m3.

8. A method of manufacturing a lightweight concrete wall panel according to any one of claims 5 to 7, characterised in that, The preparation method includes the following steps: mixing unburned hollow aggregate, expanded perlite, cement and mineral powder to obtain a mixture; mixing water reducing agent, water and the mixture to obtain lightweight concrete; sequentially forming and curing the lightweight concrete to obtain the lightweight concrete wallboard.

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