Concrete mixtures and panels including such mixtures

Abstract

The present invention relates to concrete mixtures and panels including such mixtures, which will find application in construction, and particularly in residential, industrial, bridge and road construction, in the production of concrete panels for the construction of walls for buildings, facilities and others. The created concrete mixes for panels include cement, crushed stone fractions, crushed sand, river sand, superplasticiser, and water. Concrete mixtures may also include a chemical additive that is iron silicate, and / or microsilica powder, and / or structural fibres, or carbon dioxide. Many specific variants for implementation of the concrete mixes are possible. The created panel includes any of the created concrete mixes and consists of three successively connected layers. The first layer is the concrete mixture (1) formed in a pre-built formwork bed, the second layer is a reinforcing element (2) and the third layer is a pre-sized thermal insulation material (3). The reinforcing element (2) is a welded rebar grid or structural fibres. The thermal insulation material (3) is expanded polystyrene or EPS.

Description

[0001] Concrete mixtures and panels including such mixtures

[0002] Field of technique

[0003] The present invention relates to concrete mixtures and panels including such mixtures, which will find application in construction, and particularly in residential, industrial, bridge and road construction, in the production of concrete panels for the construction of walls for buildings, facilities and others.

[0004] Prior art

[0005] Concrete mixes are a mix of dense mass that is obtained by mixing basic components in a precise ratio, such as cement, water, and crushed stone in different fractions. Depending on the intended usage of the concrete mixtures there are special requirements for each of its components, such as quantity, size, shape, purity, composition, properties. Failure to comply with the requirements leads to the impossibility of the concrete performing its assigned tasks, which is why in some cases chemical and / or mineral additives are added, which give it additional properties or strengthen the existing ones. To improve the qualities of the concrete mix and hardened concrete, plasticisers, antifreeze additives and other chemical additives are used.

[0006] From registered utility model No 2668 Ul, a composition of concrete mixture for products of various types of concrete is known, which includes the following components in the corresponding percentages by weight: cement 15%; crushed stone dust particles 0 / 0.063 mm 2.8%; sand 0 / 4 mm 43.11%; gravel 4 / 12.5 mm 33%; water 6% and chemical additive 0.09%.

[0007] From registered utility model No 3228 Ul , a multilayer panel for thermal and sound insulation is known, which consists of three consecutively connected layers. The first layer is a hard, dense layer of ceramic or terracotta or stone. The second layer is a hard layer of closed cell aluminium foam, and the third layer is a soft, plastic layer of hard-to-melt fibres obtained from natural raw materials.

[0008] Technical nature of the invention The task of the invention is to create concrete mixtures and panels, including such mixtures, which are qualitatively and economically viable, in the production of which ecological components are included, ensuring an increase in the mechanical properties and strength of concrete panels, as well as their frost resistance, thermal and waterproofing.

[0009] The task was solved by creating a concrete mixture for panels, including cement, fractions of crushed stone, sand, and water. According to the invention, the concrete mixture also includes a superplasticiser, and the components of the mixture are in the following percentages by weight: cement type CEM I 52.5 R from 16 to 18.5%, crushed sand 0 / 4 mm from 12.5 to 23%, river sand 0 / 4 mm from 16 to 23%, crushed fraction 4 / 11.2 mm from 11 to 28%, crushed fraction 11.2 / 22.4 mm from 16 to 24%, superplasticiser from 0.1 to 0.15% and water from 7 to 8%.

[0010] In a sample implementation, the components of the concrete mix are in the following percentages by weight: cement type CEM I 52.5 R is 18.1%, crushed sand 0 / 4 mm is 20.3%, river sand 0 / 4 mm is 20.3%, the 4 / 11.2 mm crushed fraction is 11%, the 11.2 / 22.4 mm crushed fraction is 23.1%, the superplasticiser is 0.1% and the water is 7.1%.

[0011] The task was solved by creating a second concrete mix for panels, including cement, crushed stone fractions, sand, and water. According to the invention, the concrete mixture includes a superplasticiser and a chemical additive, and the components of the mixture are in the following percentages by weight: cement type CEM I 52.5 R from 16 to 18.5%, crushed sand 0 / 4 mm from 12.5 to 23%, river sand 0 / 4 mm from 16 to 23%, crushed fraction 4 / 11.2 mm from 11 to 28%, crushed fraction 11.2 / 22.4 mm from 16 to 24%, superplasticiser from 0.1 to 0.15 %, chemical additive from 0.1 to 3.5% and water from 7 to 8%.

[0012] In a sample implementation of the second concrete mixture for panels, the chemical additive is iron silicate, the components of which are in the following percentages by weight: cement type CEM I 52.5 R is 17.2%, crushed sand 0 / 4 mm is 16.0%, river sand 0 / 4 mm is 18.0%, crushed fraction 4 / 11.2 mm is 16.8%, crushed fraction 11.2 / 22.4 mm is 21.2%, iron silicate is 3.3%, the superplasticiser is 0.1% and water is 7.4%.

[0013] In another sample implementation of the second concrete mixture for panels, the chemical additive is microsilica powder, and its components are in the following percentages by weight: cement type CEM I 52.5 R is 17.4%, crushed sand 0 / 4 mm is 12.9%, river sand 0 / 4 mm is 22.4%, crushed fraction 4 / 11.2 mm is 22%, crushed fraction 11.2 / 22.4 mm is 16.5%, microsilica powder is 1.2%, superplasticiser is 0.1% and water is 7.5%.

[0014] In a third sample implementation of the second concrete mixture for panels, the chemical additive is structural fibres, and its components are in the following percentages by weight: cement type CEM I 52.5 R is 18.3%, crushed sand 0 / 4 mm is 18.7%, river sand 0 / 4 mm is 16.6%, crushed fraction 4 / 11.2 mm is 20.8%, crushed fraction 11.2 / 22.4 mm is 17.5%, structural fibres are 0.1%, the superplasticiser is 0.1% and water is 7.9%.

[0015] In a fourth sample implementation of the second concrete mixture for panels, the chemical additive is carbon dioxide, and its components are in the following percentages by weight: cement type CEM I 52.5 R is 16.4%, crushed sand 0 / 4 mm is 17%, river sand 0 / 4 mm is 19.7%, crushed fraction 4 / 11.2 mm is 18%, crushed fraction 11.2 / 22.4 mm is 21.7%, carbon dioxide is 0.1%, superplasticiser is 0.1% and water is 7%.

[0016] The task was solved by creating a third concrete mixture for panels, including cement, crushed stone fractions, sand, and water. According to the invention, the concrete mixture includes a superplasticiser and chemical additives, which are iron silicate, microsilica powder and structural fibres. The components of the mixture are in the following percentages by weight: cement type CEM I 52.5 R from 16 to 18.5%, crushed sand 0 / 4 mm from 12.5 to 23%, river sand 0 / 4 mm from 16 to 23%, crushed fraction 4 / 11.2 mm from 11 to 28%, iron silicate from 2 to 4%, microsilica powder from 0.5 to 1%, superplasticiser from 0.3 to 0.6%, structural fibres from 0.1 to 0.1 % and water from 6 to 8%.

[0017] In a variant fulfilment of the third concrete mixture, its components are in the following percentages by weight: cement type CEM I 52.5 R is 18%, crushed sand 0 / 4 mm is 22.4%, river sand 0 / 4 mm is 21.2%, crushed fraction 4 / 11 .2 mm is 27.2%, iron silicate is 3%, microsilica powder is 0.8%, superplasticiser is 0.5%, structural fibres are 0.1% and water is 6.8%.

[0018] A panel was also created including any of the created concrete mixes, which consists of three sequentially connected layers. The first layer is the concrete mixture formed in a pre-built formwork bed, the second layer is a reinforcing element, and the third layer is a pre-sized thermal insulation material. The thermal insulation material is expanded polystyrene or EPS.

[0019] In one sample implementation, the reinforcing element is a welded grid of rebar.

[0020] In another sample implementation, structural fibres are used as a reinforcing element.

[0021] An advantage of the invention is that the created concrete mixtures are of high quality and economically advantageous, since their production includes ecological components that ensure an increase in mechanical properties, strength, and loadbearing capacity. The created panel, including any of the created concrete mixes, is waterproof, frost-resistant, thermal and waterproof, and is resistant to mechanical damage.

[0022] Description of the attached figures

[0023] The present invention is illustrated in the addended figures where:

[0024] Figure 1 is an axonometric view of a panel with a welded grid of rebar and thermal insulation, according to the invention; and

[0025] Figure 2 is a section along A-A of Figure 1.

[0026] Examples of embodiments of the invention

[0027] The created concrete mixtures, according to the invention, are a prerequisite for creating six variants of specific concrete mixtures used in the production of various concrete panels for the construction of walls for buildings, bridge facilities and others.

[0028] In a sample implementation, the components of the concrete mix are in the following percentages by weight: cement type CEM I 52.5 R is 18.1%, crushed sand 0 / 4 mm is 20.3%, river sand 0 / 4 mm is 20.3%, the 4 / 11.2 mm crushed fraction is 11%, the 11.2 / 22.4 mm crushed fraction is 23.1%, the superplasticiser is 0.1% and the water is 7.1%.

[0029] The concrete mixtures can also include a chemical additive that serves for better workability of the concrete mixture and with the aim of increasing durability and resistance against physical and chemical environmental influences. In a second sample implementation of the concrete mixture, the chemical additive is iron silicate, the components of the mixture being in the following percentages by weight: cement type CEM I 52.5 R is 17.2%, crushed sand 0 / 4 mm is 16.0%, river sand 0 / 4 mm is 18.0%, crushed fraction 4 / 11.2 mm is 16.8%, crushed fraction 11.2 / 22.4 mm is 21.2%, iron silicate is 3.3%, superplasticiser is 0.1% and water is 7.4%.

[0030] Iron silicate is one of the main industrial waste products in copper manufacture. It is obtained as a result of a complicated metallurgical process, which guarantees constancy of its physical and chemical characteristics. The properties of iron silicate determine its compatibility with various materials such as limestone, clay, cement, sand, gravel, construction chemicals, etc. Its application leads to the production of building materials with a lower footprint on the environment and to a reduction in the use of natural raw materials.

[0031] In a third sample implementation of the concrete mixture, the chemical additive is microsilica powder, and the components of the mixture are in the following percentages by weight: cement type CEM I 52.5 R is 17.4%, crushed sand 0 / 4 mm is 12.9%, river sand 0 / 4mm is 22.4%, crushed fraction 4 / 11.2mm is 22%, crushed fraction 11.2 / 22.4 mm is 16.5%, microsilica powder is 1.2%, superplasticiser is 0,1% and water is 7.5%.

[0032] Microsilica powder is amorphous silicon dioxide, with a high specific density, which is used as a mineral additive for concrete. During the hydration reaction between cement and water, the microsilica powder reacts with the calcium hydroxide and prevents its release, thus protecting it from interacting with salts that normally cause corrosion when reacting with the calcium hydroxide. Concrete mixtures containing microsilica powder have increased corrosion resistance, high mechanical strength, reduced capillary absorption, and increased water impermeability.

[0033] In a fourth sample implementation of the concrete mixture, the chemical additive is structural fibres, and the components of the mixture are in the following percentages by weight: cement type CEM I 52.5 R is 18.3%, crushed sand 0 / 4 mm is 18.7%, river sand 0 / 4 mm is 16.6%, crushed fraction 4 / 11.2 mm is 20.8%, crushed fraction 11.2 / 22.4 mm is 17.5%, structural fibre is 0.1%, the superplasticiser is 0.1% and water is 7.9%. The use of structural fibres in the production of facade panels has the following advantages: carbon emissions are reduced compared to equivalent steel reinforcement; they are safer and easier to use than steel; work cycles are shortened; corrosion is eliminated; the load is redistributed. By using structural fibres in the panels, the need for reinforcing steel rebar is eliminated.

[0034] In a fifth sample implementation of the concrete mixture, the chemical additive is carbon dioxide (CO2), and the components of the mixture are in the following percentages by weight: cement type CEM I 52.5 R is 16.4%, crushed sand 0 / 4 mm is 17%, river sand 0 / 4 mm is 19.7%, crushed fraction 4 / 11.2 mm is 18%, crushed fraction 11.2 / 22.4 mm is 21.7%, carbon dioxide is 0.1%, superplasticiser is 0.1% and water is 7%.

[0035] By introducing / injecting recycled CO2 into the concrete mix at the time of mixing, the carbon footprint is reduced without compromising the performance or strength of the concrete. Once injected, CO2 undergoes a process of chemical mineralization (calcium carbonate CaCOg) and becomes permanently embedded in the concrete. CO2, which is a waste product and would otherwise pollute the environment further, gives additional strength to concrete products as well as reducing the need for cement in the respective product.

[0036] In a sixth sample implementation of the concrete mixture, the components of the mixture are in the following percentages by weight: cement type CEM I 52.5 R is 18%, crushed sand 0 / 4 mm is 22.4%, river sand 0 / 4 mm is 21.2%, the crushed fraction 4 / 11.2 mm is 27.2%, iron silicate is 3%, microsilica powder is 0.8%, superplasticiser is 0.5%, structural fibre is 0.1% and water is 6.8%.

[0037] Panels made with this concrete mixture are suitable for bridge deck panels and are characterised by being frost-resistant, extremely strong and light, requiring no mechanized equipment for their lifting and installation.

[0038] The concrete mixes created are produced in a stationary concrete plant that allows automatic dosing of all components. The built concrete installation is in close proximity to the production site for the facade panels, which favours the production process from the point of view of the quality of the concrete mixture. The cement used is Portland cement CEM I 52.5 R. Its main components are clinker from 95 to 100% and additional components up to 5%. All additive materials used in the production of concrete mixes are certified and meet the requirements of BDS (Bulgarian State Standards). The crushed rock fractions used have a precisely defined grain size, which improves the compressive strength and tensile strength of the concrete. The crushed rock fractions are processed by a washing-sorting plant to increase the qualities of the concrete mixture. The content of fine particles in both sands included in the concrete mixes is kept below 3%.

[0039] The created panel shown in Figures 1 and 2 includes any of the created concrete mixes and consists of three successively connected layers. The first layer is the concrete mixture 1 formed in a pre-built formwork bed, the second layer is a reinforcing element 2 and the third layer is a pre-sized thermal insulation material 3. The reinforcing element 2 is a welded rebar grid or structural fibres. Where the panel is required to be of lower weight, structural fibres are used instead of welded rebar grid. The thermal insulation material 3 is expanded polystyrene or EPS.

[0040] The panel is manufactured in factory conditions by placing the concrete mix 1 in a pre-built formwork, adding the pre-prepared welded rebar grid or structural fibres and finally applying pre-sized thermal insulation. The panel can be cast in a formwork with a relief. In the panel itself, openings can be formed with a variety of apertures - for doors, windows, installations, and others.

[0041] During the production of the panel, all the necessary components for its installation are incorporated, such as ironmongery at the top and bottom along the entire length of the panel, as well as anchor channels for bolt connection at four points in the panel. In addition, routes for installations such as electrical cables or the heating installation, drainage pipes and others can be integrated, which speeds up the construction process.

[0042] The created panels are of varying thickness, length, and width, and can be used both as facade panels and as interior partition walls. Reinforced concrete panels are not affected by moisture and cold and are resistant to mechanical damage, and their installation does not require any preliminary construction assembly activities.

Claims

PATENT CLAIMS1. Concrete mixture for panels, including cement, fractions of crushed stone, sand and water, is characteristic by also including a superplasticiser, in which the components of the mixture are in the following percentages by weight: cement type CEM 1 52.5 R from 16 to 18.5% , crushed sand 0 / 4 mm from 12.5 to 23%, river sand 0 / 4 mm from 16 to 23%, crushed fraction 4 / 11.2 mm from 11 to 28%, crushed fraction 11.2 / 22.4 mm from 16 to 24%, superplasticiser from 0.1 to 0.15% and water from 7 to 8%.

2. The concrete mixture according to claim 1 is characteristic in that its components are in the following percentages by weight: cement type CEM I 52.5 R is 18.1%, crushed sand 0 / 4 mm is 20.3%, river sand 0 / 4 mm is 20.3%, crushed fraction 4 / 11.2 mm is 11%, crushed fraction 11 .2 / 22.4 mm is 23.1%, superplasticiser is 0.1% and water is 7.1%.

3. Concrete mixture for panels, including cement, fractions of crushed stone, sand and water, is characteristic by also including a superplasticiser and a chemical additive, the components of the mixture being in the following percentages by weight: cement type CEM 152.5 R from 16 to 18, 5%, crushed sand 0 / 4 mm from 12.5 to 23%, river sand 0 / 4 mm from 16 to 23%, crushed fraction 4 / 11.2 mm from 11 to 28%, crushed fraction 11.2 / 22 .4 mm from 16 to 24%, superplasticizer from 0.1 to 0.15%, chemical additive from 0.1 to 3.5% and water from 7 to 8%.

4. The concrete mixture according to claim 3 is characteristic in that the chemical additive is iron silicate, and its components are in the following percentages by weight: cement type CEM I 52.5 R is 17.2%, crushed sand 0 / 4 mm is 16.0 %, river sand 0 / 4 mm is 18.0%, crushed fraction 4 / 11.2 mm is 16.8%, crushed fraction 11.2 / 22.4 mm is 21.2%, iron silicate is 3.3 %, superplasticiser is 0.1% and water is 7.4%.

5. The concrete mixture according to claim 3 is characteristic in that the chemical additive is microsilica powder, its components are in the following percentages by weight: cement type CEM 152.5 R is 17.4%, crushed sand 0 / 4mm is 12.9 %, river sand 0 / 4 mm is 22.4%, crushed fraction 4 / 11.2 mm is 22%, crushed fraction 11.2 / 22.4 mm is 16.5%, microsilica powder is 1.2%, superplasticiser is 0.1% and water is 7.5%.

6. The concrete mixture according to claim 3 is characteristic in that the chemical additive is a structural fibres, and its components are in the following percentages by weight: cement type CEM I 52.5 R is 18.3%, crushed sand 0 / 4 mm is 18.7 %, river sand 0 / 4 mm is 16.6%, crushed fraction 4 / 11.2 mm is 20.8%, crushed fraction 11.2 / 22.4 mm is 17.5%, structural fibres are 0.1 %, superplasticiser is 0.1% and water is 7.9%.

7. The concrete mixture according to claim 3 is characteristic in that the chemical additive is carbon dioxide, and its components are in the following percentages by weight: cement type CEM I 52.5 R is 16.4%, crushed sand 0 / 4 mm is 17%, river sand 0 / 4 mm is 19.7%, crushed fraction 4 / 11.2 mm is 18%, crushed fraction 11.2 / 22.4 mm is 21.7%, carbon dioxide is 0.1%, superplasticiser is 0.1% and water is 7%.

8. Concrete mixture for panels comprising cement, crushed stone fractions, sand and water, is characteristic in that it also includes a superplasticiser and chemical additives which are iron silicate, microsilica powder and structural fibres, the components of the mixture being in the following percentages by weight: cement type CEM I 52.5 R from 16 to 18.5%, crushed sand 0 / 4 mm from 12.5 to 23%, river sand 0 / 4 mm from 16 to 23%, crushed fraction 4 / 11.2 mm from 11 up to 28%, iron silicate from 2 to 4%, microsilica powder from 0.5 to 1%, superplasticiser from 0.3 to 0.6%, structural fibres from 0.1 to 0.15% and water from 6 to 8 %.

9. The concrete mixture according to claim 8 is characteristic in that its components are in the following percentages by weight: cement type CEM I 52.5 R is 18%, crushed sand 0 / 4 mm is 22.4%, river sand 0 / 4 mm is 21.2%, crushed fraction 4 / 11.2 mm is 27.2%, iron silicate is 3%, microsilica powder is 0.8%, superplasticiser is 0.5%, structural fibres are 0.1% and water is 6.8%.

10. A panel comprising a concrete mixture as described in one of claims 1 to 9 is characteristic in that it consists of three sequentially connected layers, the first layer being the concrete mixture (1 ) formed in a pre-built form work bed, the second layer being the reinforcing element (2) and the third layer is presized thermal insulation material (3).

11. The panel according to claim 10 is characteristic in that the reinforcing element (2) is a welded rebar grid.

12. The panel according to claim 10 is characteristic in that the reinforcing element (2) is a structural fibre.

13. The panel according to claims 10, 11 and 12 is characteristic in that the thermal insulation material (3) is expanded polystyrene or EPS.

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