Lightweight adhesive mortar building material and method for its production

Abstract

The application discloses a light-weight adhesive mortar building material and a preparation method thereof, and comprises the following raw materials and weight parts: cement 15-25 parts, light-weight fine aggregate 25-35 parts, metakaolin 5-10 parts, redispersible latex powder 15-25 parts, hydrophobically modified cellulose ether 3-6 parts, starch ether 1-3 parts, micro-expansion agent 1.5-4 parts, water reducing agent 0.2-0.6 parts and early strength agent 0.05-0.2 parts; wherein, the light-weight fine aggregate is prepared from clay pottery sand, expanded perlite and hydrophobic agent. The light-weight adhesive mortar building material has good bonding strength, can be applied to a humid or high-temperature-difference environment, and has good bonding stability and durability.

Description

Technical Field

[0001] This invention relates to a lightweight adhesive mortar building material and its preparation method, belonging to the technical field of lightweight building materials. Background Technology

[0002] Adhesive mortar is an adhesive material that can firmly bond various materials, such as floor tiles, wall tiles, etc. While there are many adhesive materials available, cement-based adhesive mortar is widely used. Currently, with the development of green building practices focused on quality, energy conservation, and environmental protection, lightweight materials are being added to improve cement-based adhesives. This not only reduces the mortar's weight but also enhances its thermal insulation properties, making lightweight building materials increasingly prominent in adhesive mortar applications. However, lightweight materials are sensitive to changes in humidity and temperature, affecting the adhesive mortar's bonding performance. In humid environments, lightweight materials easily absorb water, which can seep into the mortar, disrupting the interfacial compatibility between the lightweight materials and other substances, thus reducing the bond strength between the mortar and the substrate. In environments with large temperature differences, the thermal expansion and contraction of lightweight materials repeatedly act on the mortar layer, creating stress at the interface between the mortar and the substrate, accelerating interface failure, and significantly reducing adhesion. Summary of the Invention

[0003] In response to at least one problem existing in the prior art, the present invention provides a lightweight adhesive mortar building material and its preparation method. The lightweight adhesive mortar building material has good bonding strength, can be used in humid or high temperature difference environments, and has good bonding stability and durability.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a lightweight adhesive mortar building material, comprising the following raw materials and their weight parts: 15-25 parts cement, 25-35 parts lightweight fine aggregate, 5-10 parts metakaolin, 15-25 parts redispersible latex powder, 3-6 parts hydrophobically modified cellulose ether, 1-3 parts starch ether, 1.5-4 parts micro-expansion agent, 0.2-0.6 parts water-reducing agent, and 0.05-0.2 parts early strength agent;

[0005] The lightweight fine aggregate is made from clay sand, expanded perlite and water-repellent agent.

[0006] The formulation of this invention contains lightweight fine aggregate, cement, metakaolin, redispersible latex powder, hydrophobically modified cellulose ether, starch ether, micro-expansion agent, water-reducing agent, and early-strength agent. The lightweight fine aggregate provides lightweight properties, improves the overall material density, and enhances its hydrophobicity through the hydrophobic agent, while also promoting the bonding force between the lightweight fine aggregate and other components. Cement, as the main cementitious material, provides sufficient bonding strength and stability after hardening. Metakaolin, as a micro-powder compensator, is a highly active mineral admixture that refines the pore structure and improves impermeability. Simultaneously, metakaolin enhances the interfacial compatibility between the lightweight fine aggregate and cement, improving the durability of the lightweight adhesive mortar building material. The redispersible latex powder, combined with other substances, helps improve the bonding strength and flexibility of the lightweight adhesive mortar building material. After adding water and stirring, the redispersible latex powder forms emulsion particles that are evenly distributed in the paste-like material, promoting adhesion. The adhesive mortar forms a film at the interface between the mortar and the tile, improving the bonding strength between them. Hydrophobically modified cellulose ether and starch ether enhance water retention and improve workability; their combined use further strengthens the adhesion of lightweight adhesive mortar and improves its stability and durability, while also promoting interfacial compatibility between lightweight fine aggregates and other substances. Micro-expansion agents compensate for the shrinkage of lightweight adhesive mortar in humid or temperature-sensitive environments, improving its density, crack resistance, and impermeability, enhancing its adhesion, stability, and durability, allowing for better adhesion to the substrate. Water-reducing agents reduce water usage, enhance the durability of lightweight adhesive mortar, improve application performance, increase construction efficiency and quality, and simultaneously improve impermeability and reduce cracking. Early-strength agents accelerate the cement hydration process, enhancing the initial strength of lightweight adhesive mortar and reducing its impact on later strength. The components in this invention work together to improve not only the bonding performance of the adhesive mortar, but also the stability and durability of the bond. It is environmentally friendly and sustainable, and the lightweight adhesive mortar building material of this invention is suitable for the field of green building materials.

[0007] This application further limits the composition mass ratio, redispersible latex powder, micro-expansion agent, water-reducing agent, early strength agent, and cellulose ether in lightweight fine aggregates, so as to further improve the moisture resistance, resistance to alternating hot and cold temperatures, impermeability, low absorption rate, bonding strength, and bonding stability and durability of lightweight adhesive mortar building materials.

[0008] Preferably, the mass ratio of lightweight fine aggregate clay sand to expanded perlite is 300:100-150, and the amount of water-repellent agent added is 0.66-0.75% of the mass of clay sand, preferably 0.66%, 0.68%, 0.7%, 0.72%, 0.75%, etc.

[0009] Preferably, the water-repellent agent is an organosilicon water-repellent agent, such as methyl siloxane water-repellent agent, organosilicon emulsion, H800 organosilicon water-repellent agent, etc., such as Wacker organosilicon water-repellent agent BS1001, and methyl siloxane salt such as sodium methyl siloxane water-repellent agent. Sodium methyl siloxane water-repellent agent and H800 organosilicon water-repellent agent are preferred.

[0010] Preferably, the particle size of the clay sand and expanded perlite is 1–5 mm.

[0011] Preferably, the preparation process of lightweight fine aggregate is as follows: first, clay sand and expanded perlite are rolled and mixed evenly, while keeping rolling and spraying evenly with 0.5% water-repellent agent solution, and continue rolling and stirring for 4 to 6 hours, and then dried at a temperature of 120 to 140°C to form lightweight fine aggregate.

[0012] The lightweight fine aggregate of this invention involves treating clay ceramsite and expanded perlite with a water-repellent agent, primarily to provide excellent bonding stability and durability. The water-repellent agent adsorbs onto the clay ceramsite and expanded perlite, allowing the active substances to be released upon contact with water. After the clay ceramsite and expanded perlite solidify, an organosilicon waterproof membrane is formed, exhibiting excellent weather resistance and durability, maintaining its waterproof effect for a long time. Simultaneously, it promotes and improves the interfacial compatibility between the lightweight fine aggregate and its constituent materials, contributing to enhanced bonding strength between interfaces in lightweight adhesive mortar building materials. The lightweight materials, clay ceramsite and expanded perlite, reduce structural load. After treatment with the water-repellent agent, the pore surfaces are partially sealed, reducing water penetration. Furthermore, they possess excellent temperature adaptability, thereby improving the lightweight fine aggregate's resistance to stress cracking in humid and temperature-changing environments, and also contributing to improved long-term stability and durability of the material.

[0013] Preferably, the redispersible latex powder is a copolymer of vinyl acetate and ethylene or a terpolymer of vinyl acetate, ethylene, and higher fatty acid vinyl esters.

[0014] Preferably, the redispersible latex powder is a copolymer of vinyl acetate and ethylene.

[0015] Preferably, the micro-expansion agent is a magnesium oxide-based expansion agent, such as lightly calcined magnesium oxide expansion agent or HME-II high-performance concrete magnesium oxide composite expansion agent, with HME-II high-performance concrete magnesium oxide composite expansion agent being the preferred choice.

[0016] Preferably, the hydrophobically modified cellulose ether is HM500 type hydrophobically modified hydroxyethyl cellulose.

[0017] Preferably, the water-reducing agent is a polycarboxylate water-reducing agent, such as maleic anhydride water-reducing agents, acrylic / methacrylic acid water-reducing agents, etc., with maleic anhydride water-reducing agents being more preferred.

[0018] Preferably, the early strength agent is an organic early strength agent, such as triethanolamine, triisopropanolamine, calcium formate, etc., with triethanolamine being the preferred choice.

[0019] The present invention also provides a method for preparing a lightweight adhesive mortar building material, comprising the following steps: mixing cement, lightweight fine aggregate, metakaolin, redispersible latex powder, hydrophobically modified cellulose ether, starch ether, micro-expansion agent, water-reducing agent and early strength agent evenly according to the above-mentioned weight parts to obtain the lightweight adhesive mortar building material.

[0020] Preferably, the specific steps of the preparation method of the above-mentioned lightweight adhesive mortar building material are as follows: first, add cement and metakaolin and mix them; then add lightweight fine aggregate, starch ether, and micro-expansion agent and mix them; then add redispersible latex powder, hydrophobic modified cellulose ether, water-reducing agent, and early strength agent and mix them; mix them evenly to obtain the lightweight adhesive mortar building material.

[0021] Preferably, the lightweight adhesive mortar building material is a mixed powder. When used, the lightweight adhesive mortar building material is mixed with water, wherein the amount of water added is 10-15% of the mass percentage of the lightweight adhesive mortar building material, preferably 10%, 11%, 12%, 12.5%, 13%, 14%, 15%, etc.

[0022] The lightweight adhesive mortar building material in this application can be used not only for bonding ceramic tiles, but also for bonding green wall materials and other wall materials, as well as for bonding floor tiles.

[0023] The beneficial effects of this invention are:

[0024] 1. The lightweight adhesive mortar building material of the present invention has a synergistic effect among its components. It not only maintains the lightweight nature of the adhesive mortar, making it a lightweight building material, but also enhances the bonding strength of the adhesive mortar, reduces water absorption, and is suitable for humid or high temperature difference environments. It has good bonding stability and durability.

[0025] 2. The lightweight adhesive mortar building material of the present invention uses a water-repellent agent to treat the lightweight material, forming a waterproof membrane on the lightweight material, which can maintain the waterproof effect for a long time, and helps to improve its weather resistance and durability. At the same time, it promotes the interfacial bonding between the lightweight material and other components, improving the overall bonding performance. In addition, the lightweight material itself has good temperature difference adaptability, which helps to improve the long-term stability and durability of the material.

[0026] 3. The lightweight adhesive mortar building material of the present invention uses hydrophobically modified cellulose ether and starch ether in combination, which not only promotes the interfacial compatibility between lightweight fine aggregates and other substances, but also enhances the bonding strength of the lightweight adhesive mortar building material.

[0027] 4. The lightweight adhesive mortar building material of the present invention uses metakaolin as a component, which not only refines the pore structure and improves impermeability, but also improves the interfacial compatibility between lightweight fine aggregate and cement, thereby further improving the durability of the lightweight adhesive mortar building material. Detailed Implementation

[0028] The following is a clear and complete description of the technical solutions in the implementation of this invention. The described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall apply.

[0029] Example 1

[0030] A lightweight adhesive mortar building material and its preparation method are disclosed below.

[0031] Step 1, Preparation of lightweight fine aggregate: First, mix clay sand with a particle size of 1-5 mm and expanded perlite with a particle size of 1-5 mm at a mass ratio of 300:125. Then, roll and mix evenly. While continuing to roll, spray 0.5% H800 organosilicon water-repellent agent solution evenly. The amount of H800 organosilicon water-repellent agent solution added is 0.68% of the mass of clay sand. Continue to roll and stir for 5 hours. Then, dry at a temperature of 130℃ to form lightweight fine aggregate.

[0032] Step 2, Preparation of lightweight adhesive mortar building material: First, add 15 parts of cement and 5 parts of metakaolin and mix them. Then add 35 parts of lightweight fine aggregate from step (1), 1 part of starch ether, 1.5 parts of HME-Ⅱ high-performance concrete magnesium oxide composite expansion agent and mix them. Then add 15 parts of vinyl acetate and ethylene copolymer powder, 3 parts of HM500 hydrophobic modified hydroxyethyl cellulose, 0.2 parts of maleic anhydride water-reducing agent and 0.05 parts of triethanolamine early strength agent and mix them evenly to obtain lightweight adhesive mortar building material.

[0033] Example 2

[0034] A lightweight adhesive mortar building material and its preparation method are disclosed below.

[0035] Step 1: The preparation of lightweight fine aggregate is the same as in Example 1;

[0036] Step 2, Preparation of lightweight adhesive mortar building material: First, add 20 parts of cement and 8 parts of metakaolin and mix. Then add 30 parts of lightweight fine aggregate from step (1), 2 parts of starch ether, 2.8 parts of HME-Ⅱ high-performance concrete magnesium oxide composite expansion agent and mix. Then add 20 parts of vinyl acetate and ethylene copolymer powder, 4.5 parts of HM500 hydrophobic modified hydroxyethyl cellulose, 0.4 parts of maleic anhydride water-reducing agent, and 0.12 parts of triethanolamine early strength agent and mix. Mix evenly to obtain lightweight adhesive mortar building material.

[0037] Example 3

[0038] A lightweight adhesive mortar building material and its preparation method are disclosed below.

[0039] Step 1: The preparation of lightweight fine aggregate is the same as in Example 1;

[0040] Step 2, Preparation of lightweight adhesive mortar building material: First, add 25 parts of cement and 10 parts of metakaolin and mix. Then add 25 parts of lightweight fine aggregate from step (1), 3 parts of starch ether, and 4 parts of HME-Ⅱ high-performance concrete magnesium oxide composite expansion agent and mix. Then add 25 parts of vinyl acetate and ethylene copolymer powder, 6 parts of HM500 hydrophobic modified hydroxyethyl cellulose, 0.6 parts of maleic anhydride water-reducing agent, and 0.2 parts of triethanolamine early strength agent and mix. Mix evenly to obtain lightweight adhesive mortar building material.

[0041] Example 4

[0042] A lightweight adhesive mortar building material and its preparation method are disclosed below.

[0043] Step 1, Preparation of lightweight fine aggregate: First, mix clay sand with a particle size of 1-5 mm and expanded perlite with a particle size of 1-5 mm at a mass ratio of 300:150. Then, roll and mix evenly. While continuing to roll, spray 0.5% of methyl silanol water-repellent agent evenly. The amount of methyl silanol water-repellent agent added is 0.7% of the mass of clay sand. Continue to roll and stir for 5 hours. Then, dry at a temperature of 130℃ to form lightweight fine aggregate.

[0044] Step 2, Preparation of lightweight adhesive mortar building material: First, add 15 parts of cement and 5 parts of metakaolin and mix them. Then add 35 parts of lightweight fine aggregate from step (1), 1 part of starch ether, and 1.5 parts of lightly calcined magnesium oxide expansion agent and mix them. Then add 15 parts of vinyl acetate ester and ethylene and higher fatty acid ethylene ester terpolymer powder, 3 parts of HM500 type hydrophobic modified hydroxyethyl cellulose, 0.4 parts of acrylic / methacrylic acid water-reducing agent and 0.1 parts of triethanolamine early strength agent and mix them evenly to obtain lightweight adhesive mortar building material.

[0045] Comparative Example 1

[0046] A lightweight adhesive mortar building material and its preparation method differ from Example 1 in that: first, 15 parts of cement and 5 parts of metakaolin are added and mixed; then, 24.6 parts of clay sand with a particle size of 1-5 mm, 10.24 parts of expanded perlite with a particle size of 1-5 mm, 0.16 parts of H800 organosilicon water-repellent agent, 1 part of starch ether, and 1.5 parts of HME-Ⅱ high-performance concrete magnesium oxide composite expansion agent are added and mixed; then, 15 parts of vinyl acetate and ethylene copolymer powder, 3 parts of HM500 hydrophobic modified hydroxyethyl cellulose, 0.2 parts of maleic anhydride water-reducing agent, and 0.05 parts of triethanolamine early strength agent are added and mixed evenly to obtain the lightweight adhesive mortar building material.

[0047] Comparative Example 2

[0048] A lightweight adhesive mortar building material and its preparation method differ from Example 1 in that: in the lightweight fine aggregate, clay sand, expanded perlite and fly ash are used as lightweight materials, and the mass ratio of clay sand, expanded perlite and fly ash is 300:120:60.

[0049] Comparative Example 3

[0050] A lightweight adhesive mortar building material and its preparation method differ from Example 1 in that: the cement content is 20 parts and metakaolin is not used.

[0051] Comparative Example 4

[0052] A lightweight adhesive mortar building material and its preparation method differ from Example 1 in that: 4 parts of HM500 hydrophobic modified hydroxyethyl cellulose are used, and starch ether is not used.

[0053] Comparative Example 5

[0054] A lightweight adhesive mortar building material and its preparation method differ from Example 1 in that B(H)-100K hydroxyethyl cellulose ether is used instead of HM500 hydrophobic modified hydroxyethyl cellulose.

[0055] Comparative Example 6

[0056] A lightweight adhesive mortar building material and its preparation method differ from Example 1 in that: calcium sulfoaluminate expansion agent is used instead of HME-II high-performance concrete magnesium oxide composite expansion agent.

[0057] Comparative Example 7

[0058] A lightweight adhesive mortar building material and its preparation method differ from Example 1 in that: vinyl acetate homopolymer powder is used instead of vinyl acetate and ethylene copolymer powder.

[0059] Performance testing

[0060] Water was added to the lightweight adhesive mortar building materials of Examples 1 to 4 and Comparative Examples 1 to 7 as shown in Table 1. The mixture was stirred evenly to form an adhesive mortar slurry. The adhesive mortar slurry was then allowed to stand and mature for 5 minutes, and then stirred for another 15 seconds to obtain the test sample. The performance was then tested according to standards JC / T547-2017 and JC / T984-2011, as shown in Tables 2 and 3.

[0061] Table 1

[0062]

[0063] Table 2

[0064]

[0065]

[0066] Table 3

[0067]

[0068] As can be seen from Tables 2 and 3 above, the lightweight adhesive mortar building materials of Examples 1 to 4 exhibit good comprehensive performance in terms of bonding strength and environmental resistance, as well as good bonding stability and durability. In particular, Examples 1 to 3 are even more outstanding. This invention uses lightweight fine aggregates that have been treated with a water-repellent agent on clay sand and expanded perlite. It also uses high-purity terephthalic acid, hydrophobic modified cellulose ether, starch ether, magnesium oxide-based expanding agent, and water-reducing agent to work synergistically with cement and lightweight fine aggregates. The synergistic effect of each component not only maintains the lightweight properties of the adhesive mortar but also enhances its bonding strength and reduces water absorption. It is suitable for humid or high-temperature environments and has good bonding stability and durability. It is a lightweight building material that is green, environmentally friendly, and sustainable. The lightweight adhesive mortar building material of this invention is suitable for the field of green building materials.

[0069] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit and essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0070] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A lightweight adhesive mortar building material, characterized in that, The product comprises the following raw materials and their weight parts: 15-25 parts cement, 25-35 parts lightweight fine aggregate, 5-10 parts metakaolin, 15-25 parts redispersible latex powder, 3-6 parts hydrophobically modified cellulose ether, 1-3 parts starch ether, 1.5-4 parts micro-expansion agent, 0.2-0.6 parts water-reducing agent, and 0.05-0.2 parts early strength agent; The lightweight fine aggregate is prepared from clay sand, expanded perlite and water-repellent agent; The water-repellent agent is an organosilicon-based water-repellent agent; The preparation process of the lightweight fine aggregate is as follows: first, clay sand and expanded perlite are rolled and mixed evenly, while keeping rolling and spraying evenly with 0.5% water-repellent agent solution, and continue rolling and stirring for 4~6 hours, and then dried at a temperature of 120~140℃ to form lightweight fine aggregate.

2. The lightweight adhesive mortar building material according to claim 1, characterized in that, The mass ratio of the lightweight fine aggregate clay sand to expanded perlite is 300:100~150, and the amount of water-repellent agent added is 0.66~0.75% of the mass of the clay sand.

3. The lightweight adhesive mortar building material according to claim 1, characterized in that, The organosilicon hydrophobic agent is either a methylsiloxane hydrophobic agent or an H800 organosilicon hydrophobic agent.

4. The lightweight adhesive mortar building material according to claim 1, characterized in that, The redispersible latex powder is a copolymer of vinyl acetate and ethylene, or the redispersible latex powder is a terpolymer of vinyl acetate, ethylene, and higher fatty acid vinyl esters.

5. The lightweight adhesive mortar building material according to claim 1, characterized in that, The hydrophobically modified cellulose ether is HM500 type hydrophobically modified hydroxyethyl cellulose; The water-reducing agent is a polycarboxylate water-reducing agent; The micro-expansion agent is a magnesium oxide-based expansion agent; The early-strength agent is an organic early-strength agent.

6. The lightweight adhesive mortar building material according to claim 5, characterized in that, The The magnesium oxide-based expansion agent is either HME-II high-performance concrete magnesium oxide composite expansion agent or lightly calcined magnesium oxide expansion agent. The polycarboxylate superplasticizer is either a maleic anhydride superplasticizer or an acrylic / methacrylic acid superplasticizer.

7. The lightweight adhesive mortar building material according to claim 1, characterized in that, The particle size of the clay sand and expanded perlite is 1~5mm.

8. The lightweight adhesive mortar building material according to claim 1, characterized in that, The lightweight adhesive mortar building material is a mixed powder. When using it, the lightweight adhesive mortar building material is mixed with water, wherein the amount of water added is 10-15% of the mass of the lightweight adhesive mortar building material.

9. A method for preparing a lightweight adhesive mortar building material according to any one of claims 1 to 8, characterized in that, The specific steps are as follows: First, add cement and metakaolin and mix them. Then, add lightweight fine aggregate, starch ether, and micro-expansion agent and mix them. Next, add redispersible latex powder, hydrophobic modified cellulose ether, water-reducing agent, and early strength agent and mix them. Mix them evenly to obtain lightweight adhesive mortar building material.

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