Light ALC board based on silicon-calcium reaction and aluminum powder foaming and preparation method thereof

Abstract

The invention relates to the technical field of ALC board production, and particularly discloses a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming and a preparation method thereof.The lightweight ALC board is prepared from, by mass, 50-55 parts of calcium material, 40-45 parts of siliceous material, 0.5-1 part of foaming agent and 1-3 parts of admixture; the calcareous material is lime or cement, and the siliceous material is sand or fly ash; the admixture comprises a foam stabilizer and a water reducing agent, and the use mass ratio of the foam stabilizer to the water reducing agent is 1: 5; the lightweight ALC board is mainly composed of the calcareous material, the siliceous material, the foaming agent and the additive, so that the prepared lightweight ALC board has the advantages of light weight, high strength, self-insulation, energy saving, seismic resistance, fire prevention, environmental protection, labor and material saving, convenient construction and the like, and the construction technology of a novel tough urban building material realizes full-dry fabricated construction and reduces the construction cost of the ALC board.

Description

Technical Field

[0001] The invention belongs to the technical field of ALC board production, and specifically relates to a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming and a preparation method thereof. Background Art

[0002] ALC board, or Autoclaved Lightweight Concrete board, is a high-performance autoclaved aerated concrete board. It uses fly ash, cement, lime, etc. as main raw materials. By adding aluminum powder as a foaming agent and undergoing high-pressure steam curing, it eventually forms a porous and specially treated steel-reinforced concrete board. This board is not only suitable for wall materials, but can also be used as roof panels.

[0003] However, since ALC boards are usually large in size and relatively heavy in weight, ALC boards need to be designed for layout before installation, and steps such as cutting, bonding, fixing and joint treatment must be performed according to the module. The construction period is long, and special joint materials are usually used for joint treatment to ensure the firmness and waterproofness of the joints, which makes it inconvenient to carry out full dry assembly construction of ALC boards, increasing the construction cost of ALC boards. Therefore, we need to propose a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming and a preparation method thereof to solve the above-mentioned problems, so that it can achieve full dry assembly construction and reduce the construction cost of ALC boards. Summary of the invention

[0004] The purpose of the present invention is to provide a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming and a preparation method thereof, which can realize full dry assembly construction, reduce the construction cost of the ALC board, and solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] A lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming, comprising the following raw materials by mass: 50-55 parts of calcium material, 40-45 parts of silicon material, 0.5-1 parts of foaming agent, and 1-3 parts of additive;

[0007] The calcareous material is set to lime or cement, and the siliceous material is set to sand or fly ash. The calcareous material and the siliceous material are first mixed, and then water is added to the mixed material to make the mixed material chemically react to form a stable hydration product.

[0008] The admixture includes a foam stabilizer and a water reducer, and the mass ratio of the foam stabilizer to the water reducer is 1:5.

[0009] Preferably, the following raw materials are included by mass: 50 parts of calcareous material, 40 parts of siliceous material, 0.5 parts of foaming agent, and 1 part of additive.

[0010] Preferably, the following raw materials are included by mass: 52 parts of calcareous material, 43 parts of siliceous material, 0.7 parts of foaming agent, and 2 parts of additive.

[0011] Preferably, the foaming agent is aluminum powder, which generates hydrogen bubbles when mixed with the hydration product, causing the concrete to expand and form a porous structure.

[0012] Based on the above-described lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming, the present invention also provides a method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming, comprising the following steps:

[0013] S1. Prepare the following raw materials according to mass ratio: 50-55 parts of calcium material, 40-45 parts of silicon material, 0.5-1 parts of foaming agent, and 1-3 parts of admixture;

[0014] S2, adding the calcareous material and the siliceous material into a mixing device according to the mass ratio for mixing and stirring, and adding water after the mixture is evenly mixed, so that the calcareous material and the siliceous material can react chemically to form a stable hydration product;

[0015] S3, adding a foaming agent to the hydration product and continuing to stir, so that the concrete expands and forms a porous structure mixture;

[0016] S4, adding admixtures to the mixture and continuing stirring to make the raw materials evenly mixed to form a slurry;

[0017] S5, injecting the slurry into the mold and letting it stand for 10-30 minutes, and using a wire saw to cut the slurry into product bodies of the required size;

[0018] S6. Place the product body into a high-pressure steam autoclave for autoclave curing at 180°C-200°C and 1.0MPa-1.2MPa for 6-12 hours;

[0019] S7. Take out the product body after autoclaving and curing to form a stable lightweight ALC board.

[0020] Preferably, in steps S2 to S4, the mixing equipment is configured as a high-efficiency mixer, and the total mixing time from adding water and stirring after the calcareous material and the siliceous material are evenly mixed to adding the admixture and mixing evenly to form a slurry is controlled within 10 minutes, and the mixing uniformity reaches more than 95%.

[0021] Preferably, in step S5, after the slurry is injected into the mold, a scraper is used to smooth the surface of the mold so that the surface of the formed product body is smooth and flat, and the mold needs to be demolded before cutting with a wire saw, and then cutting is performed.

[0022] Preferably, in step S6, the product body is subjected to autoclaving and curing to form xonotlite or tobermorite having an earthquake resistance level of 8 or above.

[0023] Preferably, in step S7, the lightweight ALC board is used in building envelope structures, exterior wall insulation, sound insulation walls, fire walls and earthquake-resistant structures.

[0024] Preferably, the lightweight ALC board is used as the exterior wall structure of the enclosure body, combined with the frame beam thin-wall wall and corner column structure reserved in the project, and doors and windows and insulation structure are arranged at the same time, which can give full play to the advantages of the ALC board's light weight, high strength, good ductility, and strong earthquake resistance, and has good thermal insulation and sound insulation performance.

[0025] The lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming and the preparation method thereof proposed in the present invention have the following advantages compared with the prior art:

[0026] 1. The lightweight ALC board of the present invention is mainly composed of calcareous material, siliceous material, foaming agent and admixture, so that the manufactured lightweight ALC board has the advantages of light weight, high strength, self-insulation, energy saving, earthquake resistance, fire prevention, environmental protection, labor saving and material saving, convenient construction, etc. The construction technology of tough urban new building materials realizes full dry assembly construction and reduces the construction cost of ALC boards.

[0027] 2. When preparing the lightweight ALC board of the present invention, the calcium material, the silicon material, the foaming agent and the additive are mixed and stirred in a mass ratio to form a slurry to ensure the uniformity of the slurry mixing, and then the slurry is injected into a mold and allowed to stand, and then the product blanks after standing are cut according to the required blank size, and then the cut blanks are autoclaved and cured, so as to improve the strength of the ALC board and enhance the durability and stability. At the same time, it also has the advantages of energy saving and environmental protection, high installation precision, prefabricated construction, reduced labor intensity of the base layer, fast installation speed, improved construction efficiency, shortened construction period, and economical cost.

[0028] 3. The lightweight ALC board prepared by the present invention is used as the external wall structure of the enclosure body, combined with the frame beam thin-wall wall and corner column structure reserved in the existing project, and doors, windows and insulation structures are set at the same time, which can give full play to the advantages of light weight, high strength, good ductility and strong earthquake resistance of the ALC board. It has good thermal insulation and sound insulation performance. Compared with ordinary thin walls, under the same building area, it can reduce the floor space of the structure, increase the usable area, and reduce the burden on the foundation. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 The figure is a flowchart of the preparation process of the lightweight ALC board of the present invention. DETAILED DESCRIPTION

[0030] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. The specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0031] Example 1

[0032] The present invention provides a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming, which includes the following raw materials by mass: 50 parts of calcium material, 40 parts of silicon material, 0.5 parts of foaming agent, and 1 part of admixture; the calcium material is set to lime or cement, and the silicon material is set to sand or fly ash, the calcium material and the silicon material are first mixed, and then water is added to the mixed material after being evenly mixed, so that the mixed material undergoes a chemical reaction to form a stable hydration product, and the amount of water added is sufficient to enable the calcium material and the silicon material to undergo a chemical reaction, and no excessive water is required;

[0033] The foaming agent is aluminum powder, which generates hydrogen bubbles when mixed with the hydration product, causing the concrete to expand and form a porous structure, so that the prepared ALC board can achieve the characteristic of being lightweight;

[0034] All raw materials are mixed in strict proportions, and the uniformity of the mixture is ensured through precise batching and mixing, and mixing operations are performed using high-efficiency mixers.

[0035] The admixture comprises a foam stabilizer and a water reducer, and the mass ratio of the foam stabilizer to the water reducer is 1:5; the foam stabilizer and the water reducer are used to improve the working performance of the slurry and the physical and mechanical properties of the final product. The commonly used foam stabilizer is set as calcium stearate or sodium dodecylbenzene sulfonate. The foam stabilizer is used to increase the mechanical strength of the bubble liquid film, prevent the bubbles from being destroyed by external forces, and make the bubble distribution in the slurry more uniform, thereby improving the lightness and thermal insulation performance of the ALC board; the water reducer is set as lignin sulfonate, naphthalene sulfonate formaldehyde polymer and polycarboxylic acid-based high-efficiency water reducer. Through the use of the water reducer, the water consumption is greatly reduced while maintaining the fluidity of the slurry, thereby reducing the cost of the product and the production energy consumption, and the water reducer disperses the cement particles to reduce the friction between the particles, making the slurry easier to stir and pour, and at the same time can also improve the strength and durability of the concrete, reduce the shrinkage rate of the concrete, and prevent cracking.

[0036] The density of the lightweight ALC board is 500kg / m 3 -700kg / m 3 , the compressive strength is 3.5MPa-5.0MPa, and the thermal conductivity is 0.12-0.16W / (mK), which makes the lightweight ALC board have excellent seismic resistance and good fire resistance. The seismic grade reaches above 8, and the fire resistance limit is not less than 2 hours. In addition, the lightweight ALC board will not release toxic substances when disasters such as fire occur, ensuring environmental safety;

[0037] Based on the above-described lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming, the present invention also provides a method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming, such as Figure 1 As shown, the following steps are included:

[0038] S1. Prepare the following raw materials according to mass ratio: 50 parts of calcium material, 40 parts of silicon material, 0.5 parts of foaming agent, and 1 part of admixture;

[0039] S2, adding the calcareous material and the siliceous material into a mixing device according to the mass ratio for mixing and stirring, and adding water after the mixture is evenly mixed, so that the calcareous material and the siliceous material can react chemically to form a stable hydration product;

[0040] The mixing equipment is configured as a high-efficiency mixer, and the total mixing time from adding water and stirring after the calcareous material and the siliceous material are evenly mixed to adding the admixture and mixing evenly to form a slurry is controlled within 10 minutes, and the mixing uniformity reaches more than 95%.

[0041] S3, adding a foaming agent to the hydration product and continuing to stir, so that the concrete expands and forms a porous structure mixture, so as to make the prepared ALC board lightweight;

[0042] S4. Add admixtures to the mixture and continue stirring to mix the raw materials evenly to form a slurry. The mixing uniformity must reach more than 95% to facilitate casting into the mold;

[0043] S5. Inject the slurry into the mold and let it stand for 10-30 minutes. Use a wire saw to cut the slurry into product bodies of the required size. The wire saw can be replaced by other cutting equipment as long as the size of the product body meets the required requirements.

[0044] After the slurry is injected into the mold, the surface of the mold needs to be smoothed with a scraper to make the surface of the formed product body smooth and flat. The mold needs to be demolded before cutting with a wire saw to facilitate the cutting of the formed sheet and then cut.

[0045] S6. Place the product body into a high-pressure steam autoclave for autoclave curing at 180°C-200°C and 1.0MPa-1.2MPa for 6-12 hours;

[0046] After autoclaving and curing, the product body forms xonotlite or tobermorite with an earthquake resistance level of 8 or above, which can not only improve the strength of the product body, but also enhance the durability and stability of the product body.

[0047] The lightweight ALC board is applied to building envelope structures, exterior wall insulation, sound insulation walls, fire walls and earthquake-resistant structures, so that the lightweight ALC board can be used in different environments.

[0048] The lightweight ALC board is used as the external wall structure of the enclosure body, combined with the frame beam thin-wall wall and corner column structure reserved in the project, and doors, windows and insulation structure are arranged at the same time, which can give full play to the advantages of the ALC board such as light weight, high strength, good ductility and strong earthquake resistance. It has good thermal insulation and sound insulation performance, and is thinner than ordinary walls. Under the same building area, it can effectively reduce the floor space occupied by the structure, increase the usable area and reduce the burden on the foundation.

[0049] S7. Take out the product body after autoclaving and curing to form a stable lightweight ALC board.

[0050] The lightweight ALC board prepared by the above method is energy-saving and environmentally friendly, has high installation precision, and is assembled in a way that reduces the labor intensity of the bottom layer, increases the installation speed, improves the construction efficiency, shortens the construction period, and is economical in cost.

[0051] It also has good thermal insulation performance, can avoid the common wall cracking problem in the traditional extruded polystyrene board external mortar insulation method, and has a beautiful exterior shape;

[0052] In addition to its excellent earthquake resistance, the new building materials for resilient cities have excellent fire resistance, are non-flammable and have good fire resistance limits. They can effectively delay the spread of fire when secondary disasters such as fire occur, and buy precious time for the evacuation and rescue of personnel. The non-toxic properties of the new building materials for resilient cities also ensure that no harmful substances will be released in the disaster-stricken environment, providing safety guarantees for post-disaster recovery and reconstruction.

[0053] Example 2

[0054] The similarities will not be repeated here. The difference from Example 1 is that a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming includes the following raw materials by mass components: 52 parts of calcium material, 43 parts of silicon material, 0.7 parts of foaming agent, and 2 parts of additive;

[0055] A method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming comprises the following steps:

[0056] S1. Prepare the following raw materials by mass ratio: 52 parts of calcium material, 43 parts of silicon material, 0.7 parts of foaming agent, and 2 parts of admixture;

[0057] S2, adding the calcareous material and the siliceous material into a mixing device according to the mass ratio for mixing and stirring, and adding water after the mixture is evenly mixed, so that the calcareous material and the siliceous material can react chemically to form a stable hydration product;

[0058] S3, adding a foaming agent to the hydration product and continuing to stir, so that the concrete expands and forms a porous structure mixture;

[0059] S4, adding admixtures to the mixture and continuing stirring to make the raw materials evenly mixed to form a slurry;

[0060] S5, injecting the slurry into the mold and letting it stand for 10-30 minutes, and using a wire saw to cut the slurry into product bodies of the required size;

[0061] S6. Place the product body into a high-pressure steam autoclave for autoclave curing at 180°C-200°C and 1.0MPa-1.2MPa for 6-12 hours;

[0062] S7. Take out the product body after autoclaving and curing to form a stable lightweight ALC board.

[0063] The lightweight ALC board made by the above process has the advantages of light weight, high strength, self-insulation, energy saving, earthquake resistance, fire resistance, environmental protection, labor and material saving, convenient construction, etc. The construction technology of tough urban new building materials realizes full dry assembly construction and reduces the construction cost of ALC boards.

[0064] Example 3

[0065] The similarities will not be repeated here. The difference from Example 1 is that a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming includes the following raw materials by mass components: 55 parts of calcium material, 45 parts of silicon material, 1 part of foaming agent, and 3 parts of additive;

[0066] A method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming comprises the following steps:

[0067] S1. Prepare the following raw materials by mass ratio: 55 parts of calcium material, 45 parts of silicon material, 1 part of foaming agent, and 3 parts of admixture;

[0068] S2, adding the calcareous material and the siliceous material into a mixing device according to the mass ratio for mixing and stirring, and adding water after the mixture is evenly mixed, so that the calcareous material and the siliceous material can react chemically to form a stable hydration product;

[0069] S3, adding a foaming agent to the hydration product and continuing to stir, so that the concrete expands and forms a porous structure mixture;

[0070] S4, adding admixtures to the mixture and continuing stirring to make the raw materials evenly mixed to form a slurry;

[0071] S5, injecting the slurry into the mold and letting it stand for 10-30 minutes, and using a wire saw to cut the slurry into product bodies of the required size;

[0072] S6. Place the product body into a high-pressure steam autoclave for autoclave curing at 180°C-200°C and 1.0MPa-1.2MPa for 6-12 hours;

[0073] S7. Take out the product body after autoclaving and curing to form a stable lightweight ALC board.

[0074] The calcium material, silicon material, foaming agent and admixture are mixed and stirred in a mass ratio to form a slurry to ensure the uniformity of the slurry mixing, and then the slurry is injected into a mold and allowed to stand, and then the product body after standing is cut according to the required body size, and then the cut body is autoclaved and cured to improve the strength of the ALC board and enhance the durability and stability. The lightweight ALC board made by the above process has the advantages of light weight, high strength, self-insulation, energy saving, earthquake resistance, fire resistance, environmental protection, labor and material saving, and convenient construction. The construction technology of new tough urban building materials realizes full dry assembly construction and reduces the construction cost of the ALC board.

[0075] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming, characterized by: The raw materials include the following by weight: 50-55 parts of calcium material, 40-45 parts of silicon material, 0.5-1 parts of foaming agent, and 1-3 parts of additive; The calcareous material is set to lime or cement, and the siliceous material is set to sand or fly ash. The calcareous material and the siliceous material are first mixed, and then water is added to the mixed material to make the mixed material chemically react to form a stable hydration product. The admixture includes a foam stabilizer and a water reducer, and the mass ratio of the foam stabilizer to the water reducer is 1:

5.

2. The lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to claim 1 is characterized by: Calculated by mass, the raw materials include: 50 parts of calcium material, 40 parts of silicon material, 0.5 parts of foaming agent and 1 part of additive.

3. The lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to claim 1 is characterized by: Calculated by mass, the raw materials include: 52 parts of calcium material, 43 parts of silicon material, 0.7 parts of foaming agent, and 2 parts of additive.

4. The lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to claim 1 is characterized by: The foaming agent is aluminum powder, which generates hydrogen bubbles when mixed with the hydration product, causing the concrete to expand and form a porous structure.

5. A method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming, based on the lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to any one of claims 1 to 4, characterized in that: The steps include: S1. Prepare the following raw materials according to mass ratio: 50-55 parts of calcium material, 40-45 parts of silicon material, 0.5-1 parts of foaming agent, and 1-3 parts of admixture; S2, adding the calcareous material and the siliceous material into a mixing device according to the mass ratio for mixing and stirring, and adding water after the mixture is evenly mixed, so that the calcareous material and the siliceous material can react chemically to form a stable hydration product; S3, adding a foaming agent to the hydration product and continuing to stir, so that the concrete expands and forms a porous structure mixture; S4, adding admixtures to the mixture and continuing stirring to make the raw materials evenly mixed to form a slurry; S5, injecting the slurry into the mold and letting it stand for 10-30 minutes, and using a wire saw to cut the slurry into product bodies of the required size; S6. Place the product body into a high-pressure steam autoclave for autoclave curing at 180°C-200°C and 1.0MPa-1.2MPa for 6-12 hours; S7. Take out the product body after autoclaving and curing to form a stable lightweight ALC board.

6. The method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to claim 5, characterized in that: In steps S2 to S4, the mixing equipment is set as a high-efficiency mixer, and the total mixing time from adding water and stirring after the calcareous material and the siliceous material are evenly mixed to adding the admixture and mixing evenly to form a slurry is controlled within 10 minutes, and the mixing uniformity reaches more than 95%.

7. The method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to claim 6, characterized in that: In step S5, after the slurry is injected into the mold, a scraper is used to smooth the surface of the mold so that the surface of the formed product body is smooth and flat, and the mold needs to be demolded before cutting with a wire saw, and then cutting is performed.

8. The method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to claim 7, characterized in that: In step S6, the product body is cured by autoclaving to form xonotlite or tobermorite with a seismic resistance level of 8 or above.

9. The method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to claim 8, characterized in that: In step S7, the lightweight ALC board is used in building envelope structures, exterior wall insulation, sound insulation walls, fire walls and earthquake-resistant structures.

10. The method for preparing a lightweight ALC board based on silicon-calcium reaction and aluminum powder foaming according to claim 9, characterized in that: The lightweight ALC board is used as the main exterior wall structure of the enclosure, combined with the frame beam thin-wall wall and corner column structure reserved in the project, and doors, windows and insulation structure are set at the same time, which can give full play to the advantages of the ALC board such as light weight, high strength, good ductility and strong earthquake resistance, and has good thermal insulation and sound insulation performance.

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