A masonry mortar and its preparation method

Abstract

This invention discloses a masonry mortar and its preparation method. The masonry mortar comprises the following raw materials in parts by weight: 20-25 parts of cementitious material, 60-70 parts of aggregate, and 10-15 parts of water, and also includes a water-reducing agent, the amount of which is 0.3-0.45 wt% of the cementitious material; the cementitious material comprises the following components in parts by weight: 20-30 parts of slag, 5-10 parts of calcareous waste slag-based material, and 65-70 parts of biomass ash slag-based material; the aggregate comprises the following components in parts by weight: 40-60 parts of zeolite sand and 40-60 parts of cave slag. This invention features low cost, high solid waste disposal, deep chloride ion removal, heavy metal stabilization and solidification, full wastewater reuse, and excellent workability and constructability. Through centralized urban treatment of cave slag and local mortar supply, it significantly reduces transportation costs and ecological disturbance, adapting to the needs of engineering construction and large-scale urban masonry.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, and more specifically, relates to a masonry mortar and its preparation method. Background Technology

[0002] Masonry mortar is a crucial building material that bonds bricks, stones, blocks, and other matrix materials into a strong whole and transfers loads. In masonry structures, it plays a vital role in bonding, cushioning, and load transfer. Compared to ordinary mortar, masonry mortar directly affects the load-bearing capacity and stability of the masonry. Therefore, its compressive strength must meet the design strength grades: M5, M7.5, M10, M15, M20, M25, and M30, and its 28-day compressive strength must also meet the standard. Furthermore, it must have good water retention to prevent water from being rapidly absorbed by the bricks, leading to incomplete cement hydration and a sharp drop in strength. Ordinary mortar has low water retention requirements, making it prone to water loss and cracking. Workability must be strictly controlled to ensure uniform, full, and non-flowing mortar joints. Higher bond strength is required to form a reliable bond with the bricks / blocks, ensuring the integrity of the masonry structure. Lower shrinkage and stricter volume stability requirements are also necessary to prevent excessive shrinkage during hardening, which can lead to cracking, air leakage, and water seepage.

[0003] Traditional masonry mortar production uses cement as a binder and natural river sand as fine aggregate, resulting in enormous carbon dioxide emissions and severe environmental and ecological damage. Natural river sand resources are increasingly depleted, and some areas have begun to restrict its mining. Furthermore, the large-scale accumulation of solid waste such as tunnel muck and tailings generated during tunnel construction and mining not only occupies significant land resources but also poses a continuous threat to the surrounding ecological environment. Therefore, using solid waste to replace natural raw materials in the preparation of masonry mortar has become an important direction for the green and low-carbon transformation of the construction industry.

[0004] Existing technologies have explored the preparation of mortar using industrial solid waste and construction waste. However, these technologies often still use natural sand as fine aggregate or ordinary silicate cement as cementing material, resulting in limited solid waste utilization. Furthermore, existing technologies sometimes involve using solid waste to prepare cementing materials, using construction waste to prepare fine aggregate for use alone in mortar, or only adding a small amount of solid waste to mortar. No mature technology for large-scale, high-proportion solid waste disposal has yet been developed. Solid waste exhibits numerous drawbacks in building material applications, hindering its widespread adoption. Summary of the Invention

[0005] The purpose of this invention is to address the above-mentioned shortcomings by providing a masonry mortar and its preparation method. Addressing the problems of high costs associated with transporting solid waste from tunnel engineering projects, tight supply of building materials in urban areas, and high transportation costs for masonry mortar, this invention uses fly ash from waste incineration, tunnel slag, slag, and carbide slag as main raw materials. The prepared masonry mortar meets the 28-day compressive strength requirements of JGJ / T 98-2010 "Specification for Mix Proportion Design of Masonry Mortar". It possesses functions such as low cost, high solid waste disposal capacity, deep chloride ion removal, heavy metal stabilization and solidification, full wastewater reuse, and excellent workability and constructability. Through centralized treatment of tunnel slag in urban areas and local mortar supply, transportation costs and ecological disturbance are significantly reduced, making it suitable for engineering construction and large-scale urban masonry needs.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: In a first aspect, the present invention provides a masonry mortar comprising the following raw materials in parts by weight: 20-25 parts of cementitious material, 60-70 parts of aggregate, and 10-15 parts of water, and further comprising a water-reducing agent, wherein the amount of water-reducing agent added is 0.3-0.45 wt% of the cementitious material; the cementitious material comprises the following components in parts by weight: 20-30 parts of slag, 5-10 parts of calcareous waste slag-based material, and 65-70 parts of biomass ash slag-based material; the aggregate comprises the following components in parts by weight: 40-60 parts of zeolite sand and 40-60 parts of slag.

[0007] Preferably, the calcareous waste residue-based material includes one or more combinations of carbide slag, steel slag, and quicklime.

[0008] Preferably, the biomass ash-based material includes one or more combinations of waste incineration fly ash, rice husk ash, sugarcane ash, and straw ash.

[0009] The cementing material described in this invention is a multi-solid waste synergistic cementing material. It activates low-activity solid waste through complementary raw material ratios. If the slag content is too low, there will be insufficient active cementing components, resulting in low early strength, loose structure, poor durability, and inability to form a stable cementing system. If the content is too high, the activity will be too high, leading to large shrinkage, easy cracking, poor volume stability, increased cost, and decreased solid waste disposal capacity. If the calcareous waste slag-based material is too low, the alkalinity activation will be insufficient, the activity activation will be inadequate, the hydration process will be slow, and the strength growth will be insufficient. If the content is too high, it will easily lead to excessive alkalinity, resulting in alkali-aggregate reaction, efflorescence, volume expansion and cracking, and a sharp decrease in durability. If the biomass ash slag-based material is too low, the silica-alumina filling phase will be insufficient, resulting in low system density, high porosity, poor strength and impermeability, and a significant reduction in solid waste disposal capacity. If the content is too high, there will be insufficient active components, insufficient cementing phase for bonding, extremely low system strength, inability to form, easy pulverization and collapse, and loss of usability.

[0010] Preferably, the zeolite sand is produced by hydrothermal reaction of waste incineration fly ash that has been ultrasonically washed with water, which realizes on-site disposal of fly ash and deep removal of chloride ions, significantly reducing the cost of raw material transportation and construction, and improving resource utilization.

[0011] This invention uses a specific ratio of zeolite sand and cavitary residue as aggregate, resulting in better gradation, lower porosity, and a more reasonable slurry demand compared to other aggregates. Through a combination of activation reaction and mechanical embedding, the interfacial transition zone is densified, strengthening the interface. If only cavitary residue is used, the particles are sharp and the gradation is poor; if only zeolite sand is used, it results in particles that are too light, too fine, and have high water absorption. Too much zeolite sand leads to porosity and high water absorption, and excessive amounts can cause a surge in the system's water demand; too much cavitary residue leads to numerous sharp edges and poor gradation.

[0012] Preferably, the aggregate is configured as medium sand in Zone 2, that is, the fineness modulus of the aggregate is between 2.3 and 3.0, and the particle size distribution meets the requirements of Zone 2 of GB / T14684-2019 "Sand for Construction".

[0013] Preferably, the water-reducing agent can be one or more of polyester-type polycarboxylate water-reducing agents, polyether-type polycarboxylate water-reducing agents, NF water-reducing agents, BC-naphthalene-based water-reducing agents, and naphthalene-based high-efficiency water-reducing agents.

[0014] In a second aspect, the present invention also provides a method for preparing the masonry mortar described in the first aspect, comprising: After being ultrasonically washed in two stages, fly ash from waste incineration is converted into zeolite sand through a hydrothermal reaction. Slag, calcareous waste residue-based materials, and biomass ash residue-based materials are mixed in a preset ratio to prepare alkali-activated cementitious materials. The alkali-activated cementitious material, the zeolite sand, the slag, water, and the water-reducing agent are mixed in a preset ratio to prepare masonry mortar.

[0015] Furthermore, the process of subjecting the fly ash from waste incineration to ultrasonic two-stage water washing includes: The fly ash from waste incineration is mixed with auxiliary agents and then subjected to ultrasonic coarse washing, followed by centrifugation to obtain a centrifuged filter cake. After mixing the centrifuged filter cake with water, it is subjected to ultrasonic two-stage washing and centrifugation to obtain fly ash filter cake with Cl⁻ content and moisture content meeting the preset indicators.

[0016] This invention utilizes ultrasonic disruption to break the liquid film on the surface of fly ash particles, promoting the migration of chloride ions from the particle interior to the liquid phase; it can also break down fly ash agglomerates, exposing encapsulated chloride salts and improving the dechlorination rate of the primary coarse wash. The specific operating steps are as follows: (1) Ultrasonic coarse cleaning Raw material input: Add raw fly ash in batches, turn on the ultrasonic transducer, and adopt the alternating mode of "30s working and 10s pausing" to control the liquid-solid ratio of 6-8mL / g, ultrasonic power of 450-500w, and ultrasonic frequency of 35-40kHz. Add auxiliary agents: Add 0.08%-0.1% of one or more of polyaluminum chloride (PAC), polyferric sulfate (PFS), and polyferric chloride (PFC), start jacket heating to 25℃-35℃, stirring speed 120r / min-200r / min, and set the total treatment time to 20min; Centrifugation: After stirring, let stand for 3-5 minutes, then feed the slurry into a disc centrifuge at a speed of 3000-4500 r / min. The filtrate after centrifugation is sent to a wastewater treatment system and, after treatment, used as mixing water for mortar. The centrifuged filter cake undergoes a secondary fine washing treatment.

[0017] (2) Ultrasonic two-stage fine cleaning Stirring: Pump the ultrasonically coarsely washed filter cake into fresh tap water at a liquid-solid ratio of 2:1-4:1 and stir at 200 r / min for 30 min; Final control separation: After centrifugation, the filter cake is tested for Cl⁻ content and moisture content. Once the content meets the standards, it enters the subsequent passivation / dispensing process. Solid-liquid separation: After washing, the slurry is centrifuged by disc centrifugation and plate and frame filter press to control the moisture content of the filter cake to ≤30% and Cl⁻ to ≤2-4%. The filtrate is sent to the wastewater treatment system and used as mixing water for mortar after treatment.

[0018] Furthermore, the method for preparing the zeolite sand includes: The fly ash filter cake obtained after ultrasonic two-stage water washing is pre-treated by ball milling, and then screened to remove impurities to obtain a ready slurry. The prepared slurry is mixed with an alkaline solution and subjected to an alkaline leaching reaction to obtain a leachate slurry; The leachate slurry was subjected to a hydrothermal crystallization reaction to obtain zeolite sand.

[0019] This invention utilizes water-washed fly ash in a hydrothermal reaction to generate zeolite sand, a step that encapsulates heavy metals. The specific operational steps are as follows: (1) Ball milling pretreatment The fly ash filter cake after secondary fine washing is mixed with kaolin, bentonite, etc., and the Si / Al ratio is controlled between 2.8 and 3.4. Then, it is ball-milled to improve the reaction contact area.

[0020] Feeding: Feed the mixture into the ball mill, add φ10mm agate balls at a ball-to-material ratio of 3:1, and add recycled water to adjust the slurry concentration to 60%; Grinding parameters: Set the rotation speed to 200-300 r / min, stop the machine and take samples after grinding for 2 hours. Use a laser particle size analyzer to detect the particle size and ensure that D50≤20μm. If it is not qualified, extend the grinding time by 30 minutes. Discharge: Qualified slurry is filtered through a 100-mesh sieve to remove impurities and unground particles.

[0021] (2) NaOH alkaline leaching reaction The slurry after screening and impurity removal is pumped into the alkaline leaching reactor for later use.

[0022] Alkali solution preparation: Dissolve industrial-grade NaOH in recycled water to prepare a 1-2 mol / L NaOH solution, and calculate the dosage according to the slurry volume ratio of 0.5:1-12:1; the alkali solution can also be prepared using KOH, Na2CO3 or K2CO3; Stepwise addition: Turn on the stirring of the reactor, set the speed to 120-150 r / min, and pump the NaOH solution into the reactor at a uniform speed. The addition time is 30 min. During the process, heat the reactor to 80℃ through the jacket, monitor the pH value in real time, and maintain the pH value range of 13-14. Constant temperature leaching: Maintain 70-80℃ and stir at 120-150r / min for 3h, and take samples every 30min to detect the silicon-aluminum dissolution rate; Cooling and ready for use: After leaching, the slurry is left in the reactor.

[0023] (3) Hydrothermal crystallization reaction The leachate slurry is added to a high-pressure reactor, heated to 130-300℃ at 5℃ / min, and kept at a constant temperature of 0.5-2MPa for 6-24 hours, with the stirring speed set to 100-150r / min.

[0024] (4) Product post-treatment and wastewater reuse After cooling, wash with recycled water until pH=8-9, dry at 105℃ for 4 hours, and sieve to classify 0.15 mm~4.75 mm zeolite sand as aggregate.

[0025] Furthermore, the specific preparation method of the alkali-activated gelling material includes: Raw material pretreatment: All solid raw materials are crushed and ground separately, and passed through an 80-mesh sieve to remove impurities and lumps; Raw material proportioning and measurement: Weigh each raw material precisely according to the preset ratio to ensure accurate proportioning.

[0026] Dry material mixing: Pour all weighed solid raw materials into a mixer and mix at low speed for 5-8 minutes until the mixture is uniform, without obvious lumps or stratification, ensuring that each component is evenly dispersed to obtain alkali-activated gelling material.

[0027] Furthermore, the specific preparation method of the masonry mortar includes: Raw material preparation and pretreatment: Prepare the slag, water-reducing agent, mixing water, and the prepared alkali-activated cementitious material and zeolite sand in advance; Precise measurement: Weigh each component according to the preset ratio to ensure accurate proportions; Dry material mixing: Pour the weighed alkali-activated cementitious material, zeolite sand and slag into the mixer and stir at low speed for 3-5 minutes until the three dry materials are evenly mixed without obvious lumps or stratification, ensuring that the aggregate and cementitious material are fully dispersed and integrated. Add water and water-reducing agent: Slowly add water-reducing agent and mixing water to the dry material mixture, while stirring at high speed for 8-10 minutes until a uniform, non-segregated, non-lumpy, and appropriately fluid masonry mortar is formed.

[0028] Furthermore, the mixing water used to prepare the masonry mortar is obtained from wastewater treated after ultrasonic secondary water washing.

[0029] Compared with the prior art, the beneficial effects of the present invention are as follows: The masonry mortar described in this invention achieves high performance and high solid waste utilization under low-cost constraints through specific material selection and proportioning. First, this invention optimizes the cementitious material system. Unlike traditional technologies that rely on single cementitious systems such as cement, lime, and metakaolin, this invention does not rely on cement or require highly active mineral admixtures. It achieves the transformation of low-activity solid waste into high-value cementitious materials through the complementary activation of multiple solid wastes, breaking the inherent technical prejudice that high-performance materials must rely on highly active cementitious materials. Second, the specific material proportioning overcomes the technical bottlenecks of high water demand, poor water retention, and segregation in mortar with high solid waste content. This endows the mortar with excellent cohesiveness and smoothness during construction, significantly improving on-site masonry efficiency, and ensuring that the compressive strength of the prepared masonry mortar meets the requirements of JGJ / T standards. The 98-2010 "Code for Design of Mix Proportion of Masonry Mortar" requires and ensures the durability and safety of masonry structures. Furthermore, this invention transforms solid waste materials such as slag from waste sites into high-value-added green building materials. It can synergistically consume multiple sources of solid waste, including metallurgical slag, chemical slag, waste incineration fly ash, and agricultural and forestry ash, solving common industry problems such as land occupation by industrial solid waste, heavy metal risks from waste fly ash, and low utilization rates of agricultural and forestry ash in one go, achieving 100% resource utilization, harmlessness, and high-value utilization of solid waste.

[0030] The mortar preparation method provided by this invention utilizes incinerated fly ash to prepare zeolite sand, achieves deep removal of chloride ions through ultrasonic two-stage water washing, and achieves stable solidification of heavy metals through hydrothermal synthesis. The wastewater obtained from ultrasonic water washing is then treated and used for subsequent mortar mixing, realizing the full recovery and recycling of saline and solid wastewater during the treatment process, constructing a closed-loop production system with zero wastewater discharge. This significantly reduces water consumption while achieving a high proportion of synergistic disposal of solid waste, resulting in significant green, low-carbon, and ecological environmental protection benefits. The centralized treatment of tunnel slag in urban areas and the local supply of mortar greatly reduce transportation costs and ecological disturbance, adapting to the needs of engineering construction and large-scale urban masonry. Detailed Implementation

[0031] Preferred embodiments of the present invention will now be described in more detail with reference to specific examples.

[0032] In the following description, certain specific details are set forth for the purpose of illustrating various disclosed embodiments in order to provide a thorough understanding of the various disclosed embodiments. However, those skilled in the art will recognize that embodiments may be practiced without one or more of these specific details. In other instances, well-known apparatuses, structures, and techniques associated with this application may not have been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments.

[0033] Unless the context requires otherwise, throughout the specification and claims, the word “comprising” and its variations, such as “including” and “having”, shall be understood to have an open, inclusive meaning, that is, to be interpreted as “including, but not limited to”.

[0034] Throughout this specification, references to "an embodiment" or "an embodiment" indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Therefore, the appearance of "in an embodiment" or "an embodiment" in various places throughout the specification does not necessarily refer to the same embodiment. Furthermore, a particular feature, structure, or characteristic may be combined in any manner in one or more embodiments.

[0035] The singular forms “a” and “the” used in this specification and the appended claims include plural references unless otherwise expressly stated herein. It should be noted that the term “or” is generally used to mean “and / or” unless otherwise expressly stated herein.

[0036] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0037] Unless otherwise specified, the experimental methods used in the following examples are conventional methods, and the materials and reagents used are commercially available.

[0038] Example 1 This embodiment provides a masonry mortar, the preparation method of which includes the following steps: S1: Ultrasonic two-stage water washing of fly ash from waste incineration S1.1 Ultrasonic coarse cleaning Ultrasonic disruption can break the liquid film on the surface of fly ash particles, promoting the migration of chloride ions from the particle interior to the liquid phase; it can also destroy fly ash aggregates, exposing encapsulated chloride salts and improving the dechlorination rate of the first-stage coarse washing. The specific operating steps are as follows: S1.1.1 Raw material input: Add raw fly ash in batches, turn on the ultrasonic transducer, and adopt the alternating mode of "30s working and 10s pausing" to control the liquid-solid ratio of 6mL / g, ultrasonic power of 450w, and ultrasonic frequency of 35kHz. S1.1.2 Addition of auxiliary agents: Add polyaluminum chloride (PAC) to cause fly ash to precipitate during water washing. The dosage of PAC is 20-50g per cubic meter of water. Start the jacket heating to 25℃-35℃, the stirring speed is 150r / min, and the total treatment time is set to 20min. S1.1.3 Centrifugation: After stirring, let stand for 5 minutes, then send the slurry into a disc centrifuge at a speed of 3000-4500 r / min. The filtrate after centrifugation is sent to the wastewater treatment system and, after treatment, is used as mixing water for mortar. The centrifuged filter cake undergoes secondary fine washing treatment.

[0039] S1.2 Secondary Fine Wash S1.2.1 Stirring: Pump the ultrasonically coarsely washed filter cake into fresh tap water at a liquid-to-solid ratio of 3:1 and stir at 200 r / min for 30 min; S1.2.2 Final control separation: After centrifugation, the Cl⁻ content and moisture content of the filter cake are tested and found to be within the standard before proceeding to the subsequent passivation / dispensing stage; S1.2.3 Solid-liquid separation: After washing, the slurry is centrifuged by disc centrifugation and plate and frame filter press to control the moisture content of the filter cake to ≤30% and Cl⁻ to ≤2-4%. The filtrate is sent to the wastewater treatment system and used as mixing water for mortar after treatment.

[0040] The gradation of each component in the waste incineration fly ash used in the above steps is shown in Table 1.

[0041] Table 1: Chemical composition of fly ash from waste incineration

[0042] S2: Zeolite sand synthesis The fly ash after washing is used in a hydrothermal reaction to produce zeolite, a step that encapsulates heavy metals.

[0043] S2.1 Ball Milling Pretreatment The fly ash filter cake after secondary fine washing is mixed with kaolin and bentonite, and the Si / Al ratio is controlled between 2.8 and 3.4. Then, it is ball-milled to improve the reaction contact area.

[0044] S2.1.1 Feeding: Feed the fly ash filter cake, kaolin, bentonite and mixed materials into the ball mill, add φ10mm agate balls at a ball-to-material ratio of 3:1, and add recycled water (recycled water obtained after wastewater treatment of wastewater from ultrasonic washing) to adjust the slurry concentration to 60%; S2.1.2 Grinding parameters: Set the rotation speed to 200 r / min, stop the machine and take samples after grinding for 2 hours. Use a laser particle size analyzer to detect the particle size and ensure that D50≤20μm. If it is not qualified, extend the grinding time by 30 minutes. S2.1.3 Discharge: Qualified slurry is filtered through a 100-mesh sieve to remove impurities and unground particles.

[0045] S2.2 NaOH alkaline leaching reaction The slurry after screening and impurity removal is pumped into the alkaline leaching reactor for later use.

[0046] S2.2.1 Alkali solution preparation: Dissolve industrial-grade NaOH in recycled water to prepare a 1 mol / L NaOH solution, and calculate the dosage according to the slurry volume ratio of 1:1; S2.2.2 Stepwise addition: Turn on the stirring of the reactor and set the speed to 120-150 r / min. Pump the NaOH solution into the reactor at a uniform speed for 30 min. During the process, heat the reactor to 80℃ through the jacket and monitor the pH value in real time to maintain the pH value range of 13-14. S2.2.3 Constant temperature leaching: Maintain 70-80℃ and stir at 120-150r / min for 3h, and take samples every 30min to detect the silicon-aluminum dissolution rate; S2.2.4 Cooling and Preparing for Use: After leaching is completed, the slurry is left in the reactor.

[0047] (3) Hydrothermal crystallization reaction The leachate slurry is added to a high-pressure reactor, heated to 130-300℃ at 5℃ / min, and kept at a constant temperature of 0.5-2MPa for 6-24 hours, with the stirring speed set to 100-150r / min.

[0048] (4) Product post-treatment and wastewater reuse After cooling, wash with recycled water until pH=8-9, dry at 105℃ for 4 hours, and sieve to classify 0.15 mm to 4.75 mm zeolite sand as aggregate. Adjust the fineness modulus using the sieved and classified fine aggregate.

[0049] S3: Preparation of alkali-activated cementitious materials S3.1 Raw material pretreatment: Crush and grind the slag, carbide slag and waste incineration fly ash separately, and pass them through an 80-mesh sieve to remove impurities and lumps; S3.2 Raw material proportioning and measurement: Weigh out 20kg of slag, 10kg of calcium carbide slag, and 70kg of waste incineration fly ash; S3.3 Dry material mixing: Pour all weighed solid raw materials into a mixer and mix at low speed for 8 minutes until the mixture is uniform, without obvious lumps or stratification, ensuring that each component is evenly dispersed to obtain alkali-activated gelling material.

[0050] S4: Preparation of masonry mortar S4.1 Raw material preparation and pretreatment: Prepare in advance the alkali-activated cementitious material prepared in step S3, the zeolite sand prepared in step S2, the slag (which needs to be crushed and cleaned before ball milling, with the same particle size distribution as the zeolite sand), the polyester-type polycarboxylate superplasticizer, and the mixing water (reclaimed water obtained after wastewater treatment from ultrasonic washing). S4.2 Precise Measurement: Weigh out 20kg of alkali-activated cementitious material, 30kg of zeolite sand, 30kg of slag, 10kg of mixing water, and 60g of polyester-type polycarboxylate superplasticizer; S4.3 Dry material mixing: Pour the weighed alkali-activated cementitious material, zeolite sand and slag into the mixer and mix at low speed for 5 minutes until the three dry materials are mixed evenly without obvious lumps or stratification, ensuring that the aggregate and cementitious material are fully dispersed and integrated. S4.4 Add water and mix water-reducing agent: Slowly add water-reducing agent and mixing water to the dry material mixture, while stirring at high speed for 10 minutes until a uniform, non-segregated, non-lumpy, and appropriately fluid masonry mortar is formed.

[0051] The gradation of each component in the slag, carbide slag, and cave slag used in the above steps is shown in Table 2.

[0052] Table 2: Gradation (%) of each component in slag, carbide slag and cave slag

[0053] Example 2 This embodiment provides a masonry mortar. Based on embodiment 1, the amount of mortar raw materials is changed to 25 kg of alkali-activated cementitious material, 35 kg of zeolite sand, 35 kg of slag, 15 kg of mixing water, and 112.5 g of polyester-type polycarboxylate superplasticizer; other steps are the same as in embodiment 1.

[0054] Example 3 This embodiment provides a masonry mortar. Based on embodiment 1, the amount of mortar raw materials is changed to 20 kg of alkali-activated cementitious material, 35 kg of zeolite sand, 30 kg of slag, 10 kg of mixing water, and 80 g of polyester-type polycarboxylate superplasticizer; other steps are the same as in embodiment 1.

[0055] Example 4 This embodiment provides a masonry mortar. Based on embodiment 1, the raw materials for preparing alkali-activated cementitious materials are changed to 30 kg of slag, 5 kg of calcium carbide slag, and 65 kg of waste incineration fly ash; all other steps are the same as in embodiment 1.

[0056] Example 5 This embodiment provides a masonry mortar. Based on embodiment 1, the raw materials for preparing alkali-activated cementitious materials are changed to 20 kg of slag, 5 kg of steel slag, 5 kg of quicklime, 40 kg of waste incineration fly ash, and 30 kg of rice husk ash; all other steps are the same as in embodiment 1.

[0057] Comparative Example 1 This comparative example provides a method for preparing masonry mortar. Based on Example 1, steps S1 and S2 are removed, commercially available conventional zeolite sand is used, and ordinary tap water is used in the remaining steps. All other steps are the same as in Example 1.

[0058] Comparative Example 2 This comparative example provides a method for preparing masonry mortar. Based on Example 1, steps S1 and S2 are removed, zeolite sand is not used, all aggregates are slag, ordinary tap water is used in the remaining steps, and all other steps are the same as in Example 1.

[0059] Comparative Example 3 This comparative example provides a method for preparing masonry mortar. Based on Example 1, the material dosage is changed to 15 kg of cementitious material, 70 kg of aggregate, 10 kg of water, and 45 g of water-reducing agent. All other steps are the same as in Example 1.

[0060] Comparative Example 4 This comparative example provides a method for preparing masonry mortar. Based on Example 1, the material dosage is changed to 20 kg of cementitious material, 60 kg of aggregate, 15 kg of water, and 60 g of water-reducing agent. All other steps are the same as in Example 1.

[0061] The performance comparison of the mortars prepared in the above embodiments and comparative examples is shown in Table 3.

[0062] Table 3: Performance Comparison of Mortars Prepared in the Examples and Comparative Examples

[0063] The various embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and principles of the described embodiments, and these modifications and variations should also be considered within the scope of protection of the present invention.

Claims

1. A type of masonry mortar, characterized in that, The raw materials include the following parts by weight: 20-25 parts of cementitious material, 60-70 parts of aggregate, and 10-15 parts of water, and also include a water-reducing agent, wherein the amount of water-reducing agent added is 0.3-0.45 wt% of the cementitious material; the cementitious material includes the following components by weight: 20-30 parts of slag, 5-10 parts of calcareous waste slag-based material, and 65-70 parts of biomass ash slag-based material; the aggregate includes the following components by weight: 40-60 parts of zeolite sand and 40-60 parts of slag.

2. The masonry mortar according to claim 1, characterized in that, The calcium-based waste residue material includes one or more combinations of carbide slag, steel slag, and quicklime.

3. The masonry mortar according to claim 1, characterized in that, The biomass ash-based material includes one or more combinations of waste incineration fly ash, rice husk ash, sugarcane ash, and straw ash.

4. The masonry mortar according to claim 1, characterized in that, The zeolite sand is obtained by hydrothermal reaction of fly ash from waste incineration that has been ultrasonically washed with water.

5. The masonry mortar according to claim 1, characterized in that, The aggregate is configured as medium sand in zone two.

6. The masonry mortar according to claim 1, characterized in that, The water-reducing agent is one or more of the following: polyester-type polycarboxylate water-reducing agent, polyether-type polycarboxylate water-reducing agent, NF water-reducing agent, BC-naphthalene-based water-reducing agent, and naphthalene-based high-efficiency water-reducing agent.

7. A method for preparing masonry mortar according to any one of claims 1 to 6, characterized in that, include: After being dechlorinated by ultrasonic two-stage water washing, fly ash from waste incineration is converted into zeolite sand through a hydrothermal reaction. Slag, calcareous waste residue-based materials, and biomass ash residue-based materials are mixed in a preset ratio to prepare alkali-activated cementitious materials. The alkali-activated cementitious material, the zeolite sand, the slag, water, and the water-reducing agent are mixed in a preset ratio to prepare masonry mortar.

8. The method for preparing masonry mortar according to claim 7, characterized in that, The process of dechlorinating fly ash from waste incineration through ultrasonic two-stage water washing includes: The fly ash from waste incineration is mixed with auxiliary agents and then subjected to ultrasonic coarse washing, followed by centrifugation to obtain a centrifuged filter cake. After mixing the centrifuged filter cake with water, it is subjected to ultrasonic two-stage washing and centrifugation to obtain fly ash filter cake with Cl⁻ content and moisture content meeting the preset indicators.

9. The method for preparing masonry mortar according to claim 7, characterized in that, The method for preparing the zeolite sand includes: The fly ash filter cake obtained after ultrasonic two-stage water washing and dechlorination is pre-treated by ball milling, and then screened to remove impurities to obtain a ready slurry. The prepared slurry is mixed with an alkaline solution and subjected to an alkaline leaching reaction to obtain a leachate slurry; The leachate slurry was subjected to a hydrothermal crystallization reaction to obtain zeolite sand.

10. The method for preparing masonry mortar according to claim 7, characterized in that, The water used to prepare the masonry mortar was obtained from wastewater treated after ultrasonic two-stage water washing.

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