Binder composition for the construction industry containing pozzolanic materials and large amounts of fillers

Abstract

The present invention relates to a binder composition comprising: a. Portland cement, lime or a mixture thereof in an amount of 10% to 49% by dry mass; b. at least one pozzolanic material in an amount of 10% to 49% by dry mass; c. at least one filler in an amount of 21% to 80% by dry mass; d. at least one activator in an amount of 0.1% to 10% by dry mass based on the total mass of components a, b and c; e. at least one rheology enhancer in an amount of 0.05% to 1.5% by dry mass based on the total mass of components a, b and c, wherein the filler is a particle mixture of - particles having a size d of 0.05 μm or more and strictly less than 8 μm, in an amount of 10% to 100% by mass based on the total mass of the filler, and - particles having a size d of 8 μm or more and strictly less than 200 μm, in an amount of 0% to 90% by mass based on the total mass of the filler. 50 50 The present invention relates to a binder composition which is a particle mixture of particles having a size d of 0.05 μm or more and strictly less than 8 μm, in an amount of 10% to 100% by mass based on the total mass of the filler, and particles having a size d of 8 μm or more and strictly less than 200 μm, in an amount of 0% to 90% by mass based on the total mass of the filler.

Description

Technical Field

[0001] The present disclosure relates to the field of mortars and concrete formulations based on low-carbon binders containing high-volume fillers for preparing concrete or industrial mortar. The technical field of the present invention relates to hydraulic mineral binders containing at least one pozzolanic material (such as volcanic ash or calcined clay) used in compositions that can set and harden, such as mortar or concrete compositions.

[0002] More specifically, the present invention relates to binders and compositions that can set and harden for the construction industry, comprising at least one pozzolanic binder and at least one limestone filler having a predetermined particle size distribution.

[0003] The present invention also relates to methods for preparing these pozzolanic binders and methods for preparing these compositions that can set and harden.

[0004] Regardless of enhancing mechanical performance or being rheologically relevant, the use of certain admixtures in such construction applications is also within the scope of the present invention.

Background Art

[0005] The production of Portland cement has a strong negative impact on the environment due to the emission of a large amount of carbon dioxide. In cement production, CO2 is essentially produced by the decarbonation of limestone during the firing of raw materials at a very high temperature (1450 °C) in a kiln (Equation (1)). CaCO3(s) → CaO(s) + CO2(g) (Equation (1))

[0006] Furthermore, carbon dioxide is emitted as a result of the combustion of fossil fuels required to heat the cement kiln. Adding additional emissions from grinding, approximately 1 ton of CO2 is obtained per ton of Portland cement. Overall, the cement industry accounts for about 7 - 9% of the world's total carbon dioxide emissions.

[0007] Furthermore, handling Portland cement can cause health problems (such as allergies) due to its particularly high alkalinity (pH exceeding 13). Additionally, harmful elements such as hexavalent chromium (Cr(VI)) may be released during mixing, and if this comes into contact with the skin, it can also harm the health of workers. Cr(VI) reducing agents (such as ferrous sulfate) are usually contained in cement powder, but their effectiveness is time-limited. Construction workers, especially those in the third world, are not expected to frequently check the deadlines associated with such treatments.

[0008] Most of the latest research on new binders aims to replace cement in various applications with binders that have a smaller environmental impact. One route is by using resources with limited processing, such as natural pozzolans of either volcanic or sedimentary origin and artificially produced pozzolans such as calcined clay. When ground into fine powder, cementitious materials can be obtained that can be used to partially replace cement or can be used alone by adding some chemical activators.

[0009] It is important to note that the use of pozzolans, whether natural or artificial, is not only environmentally friendly but also, when used in mortar and concrete, brings several enhanced properties, such as high resistance to sulfate deterioration, low permeability, good resistance in chemically aggressive environments, low heat of hydration (required for heavy buildings), generally excellent durability, and the possibility of fixing heavy metals or radionuclides. Summary of the Invention Problems to be Solved by the Invention

[0010] In this situation, the present invention aims to address at least one of the above problems and / or needs by fulfilling at least one of the following objectives. -O1- To provide a binder composition, mortar composition or concrete composition containing pozzolan and ground limestone, which is an attractive alternative to ordinary Portland cement (OPC) - based compositions. -O2- To provide an environmentally friendly binder composition, mortar composition or concrete composition containing pozzolan and ground limestone. -O3- To provide a binder composition, mortar composition or concrete composition containing pozzolan and ground limestone, which is more acceptable than OPC - based compositions with respect to health and safety issues. -O4- To provide a binder composition, mortar composition or concrete composition containing pozzolan and ground limestone, which results in dry mortar, dry and semi - dry precast concrete, and wet mortar and fresh concrete formulations having appropriate capabilities manufactured by several methods such as vibration compaction, spraying, troweling, casting, etc. -O5- To provide a binder composition, mortar or concrete composition containing pozzolan and ground limestone, which results in a wet formulation having appropriate rheological properties, i.e., a stable rheology (good workability), during the normal setting time required by the user of the wet formulation (e.g., several minutes to several hours). -O6- To provide a binder composition, mortar composition or concrete composition containing pozzolan and ground limestone, which results in a hardened product having the required mechanical properties, especially acceptable early strength (e.g., 24 hours). -O7- To provide a binder composition, mortar composition or concrete composition containing pozzolan and ground limestone, which results in a hardened product having the required durability. -O8- To provide a binder composition, mortar composition or concrete composition containing pozzolan and ground limestone, which results in a hardened product having the normal setting time required (e.g., several minutes to several hours). -O9- To provide a simple and inexpensive method for preparing a binder composition, mortar composition or concrete composition containing pozzolan and ground limestone, in accordance with at least one of Objectives - O1 - to - O8. -O10- To provide a simple and inexpensive method for preparing a binder composition, a wet mortar composition, or a fresh concrete composition in a wet form containing pozzolan and ground limestone. -O11- To provide a hardened body for the construction industry containing pozzolan and ground limestone as at least a partial binder.

Means for Solving the Problems

[0011] At least one of the above objects is a. 10% to 49% by dry mass of a clinker source, a lime source, or a mixture thereof, and b. 10% to 49% by dry mass of at least one pozzolan material, and c. 21% to 80% by dry mass of at least one filler, and d. At least one activator in an amount of 0.1% to 10% by dry mass based on the total mass of components a, b, and c, and e. At least one rheology enhancing admixture in an amount of 0.05% to 1.5% by dry mass based on the total mass of components a, b, and c A binder composition comprising: wherein the filler is - Particles in which d 50 is 0.05 μm or more and strictly less than 8 μm, in an amount of 10% to 100% by mass based on the total mass of the filler, and - Particles in which d 50 is 8 μm or more and strictly less than 200 μm, in an amount of 0% to 90% by mass based on the total mass of the filler is a particle mixture of The rheology enhancing admixture is (E1) contains at least one water-reducing polymer, and (E2) optionally may contain a wetting agent and / or a surfactant, and The water-reducing polymer (E1) is polyethylene glycol having a terminal phosphonate group and / or the following monomer units: - Unit UA

[0012]

Chemical formula

[0013] - Unit UB

[0014] [Chem.]

[0015] - Unit UC

[0016] [Chem.]

[0017] - Unit UD

[0018] [Chem.]

[0019] (wherein

[0020] [Chem.]

[0021] represents the bonding site of the monomer unit, the amount of monomer unit UA is 0 to 40 mol%, the amount of monomer unit UB is 25 to 95 mol%, the amount of monomer unit UC is 5 to 50 mol%, the amount of monomer unit UD is 0 to 25 mol%, R1 and R2 are independently hydrogen or methyl, Z1 is a bond, methyl or ethyl, Z2 is a bond, -CH2CH2O-, -CH2CH2OCH2CH2O- or -CH2CH2CH2CH2O-, R3 is -(CH2CH2O) m -R4, -(CH(CH3)CH2O) n-R4 or -(CH2CH2OCH(CH3)CH2O) y is -R4, m, n and y are independently integers from 7 to 100, R4 is hydrogen or methyl, R5 is hydrogen, methyl or -CH2COOH, R6 is -OH, -OCH2OH, -OCH2CH2OH, -OCH2CH2CH2OH, -OCH2CH(CH3)CH2OH, -OCH2CH2CH2CH2OH, -NHR7, a group retaining a phosphate functional group, a group retaining a phosphonate functional group or a group retaining a sulfonate functional group, R7 is a saturated or unsaturated, straight-chain or branched-chain having 2 to 12 carbon atoms and finally one or more heteroatoms, preferably O, N or S) is a copolymer containing, a wetting agent and / or a surfactant reduces the surface tension of water to less than 68 mN.m -1 and the wetting agent is selected from the group consisting of, preferably consisting of, glycol compounds and has a molecular weight of 60 g.mol -1 ~130 g.mol -1 and the surfactant has a molecular weight of 131 g.mol -1 ~300 g.mol -1 is achieved by a binder composition. The present invention also relates to a dry concrete composition or an industrial dry mortar composition, particularly a tile adhesive, a coating, an assembly mortar, a repair mortar, a primer, a technical mortar and a floor finishing mortar, comprising at least one aggregate and the above-described binder composition.

[0022] The present invention further relates to a fresh concrete composition or an industrial wet mortar composition, particularly a tile adhesive, a coating, an assembly mortar, a repair mortar, a primer, a technical mortar and a floor finishing mortar, comprising at least one aggregate, the above-described binder composition and water.

[0023]

[0024] ​ The present invention further relates to a hardened concrete composition or a hardened industrial mortar composition obtained from the above-described fresh concrete composition or industrial wet mortar composition.

[0025] Furthermore, the present invention relates to a method for preparing the above-described fresh concrete composition or industrial wet mortar composition, which includes a step of mixing water, at least one aggregate, and the above-described binder composition, and the binder composition is prepared separately and / or in the form of a premix from at least some of the different components of the binder composition either before or during the mixing step.

[0026] The present invention relates to the use of the above-described binder composition for improving the rheology of a fresh concrete composition or industrial wet mortar composition, particularly in the fresh state of tile adhesives, coatings, assembly mortars, repair mortars, primers, technical mortars, and floor finishing mortars, such as the yield stress and viscosity in the fresh state.

[0027] Definitions According to the terms of this text, the following non-limiting definitions need to be considered.

[0028] "Pozolanic material" is understood to mean a powdery substance that hardens by adding a mixture of water and any CaO source derived from natural or natural resources to which a temperature control treatment has been applied.

[0029] "Filler" refers to a material whose main role in the binder is physical rather than chemical. Fillers occupy pores and are used as substitutes for hydraulic binders and auxiliary cementitious materials because they consume less energy. Here, this term refers to ground limestone, ground dolomite, marble powder, silica sand, recycled concrete fine aggregate, or a mixture thereof.

[0030] "Binder" refers to a "hydraulic binder" meaning any material such as cement that hardens by adding only water.

[0031] "Cement" is understood to mean a powdery substance produced for use in manufacturing mortar or concrete. It is a mineral binder that contains as few organic compounds as possible. It refers to any ordinary cement, including ordinary Portland cement, blends of ordinary Portland cement, pozzolanic materials and / or fillers, and alkali-activated cement.

[0032] "Clinker" is understood to be the main constituent phase of ordinary Portland cement obtained by simultaneously firing limestone and an aluminosilicate source.

[0033] "Mortar" refers to a material composed of a binder, aggregates such as sand, and other components such as admixtures.

[0034] "Dry concrete" refers to a material composed of a binder, aggregates such as sand and gravel, and other components such as admixtures. "Fresh concrete" refers to a material composed of a binder, aggregates such as sand and gravel, and other components such as admixtures, and water. "Hardened concrete" refers to the hardened body obtained from fresh concrete after reaction and evaporation of water.

[0035] "d 50 " indicates the median diameter (usually in micrometers for cementitious materials) of the particle size distribution of the material. It means that 50% of the particles are of a size less than d 50 and 50% of the particles are of a size greater than d 50 . The measurement of d 50 is performed by laser diffraction analysis, also known as laser diffraction spectroscopy, using a laser diffraction analyzer, such as the "Mastersizer 2000" commercialized by Malvern Instruments that uses the wet method.

DETAILED DESCRIPTION OF THE INVENTION

[0036] Binder Composition The binder composition according to the present invention is a. A clinker source, lime source, or a mixture thereof, at 10% to 49% by dry mass, b. At least one pozzolanic material, at 10% to 49% by dry mass, c. At least one filler, at 21% to 80% by dry mass, d. At least one activator, at 0.1% to 10% by dry mass based on the total mass of components a, b, and c, e. At least one rheology-enhancing admixture, at 0.05% to 1.5% by dry mass based on the total mass of components a, b, and c comprising, wherein the filler is - Particles where d is 0.05 μm or more and strictly less than 8 μm, at 10% to 100% by mass based on the total mass of the filler, and 50 - Particles where d is 8 μm or more and strictly less than 200 μm, at 0% to 90% by mass based on the total mass of the filler - Particles where d is 8 μm or more and strictly less than 200 μm, at 0% to 90% by mass based on the total mass of the filler 50 a particle mixture of and the rheology-enhancing admixture is (E1) comprising at least one water-reducing polymer, and (E2) optionally may contain a wetting agent and / or a surfactant, wherein the water-reducing polymer (E1) is polyethylene glycol retaining a terminal phosphonate group and / or the following monomer units: - Unit UA - Unit UA

[0037]

Chemical formula

[0038] - Unit UB

[0039]

Chemical formula

[0040] - Unit UC

[0041]

Chemical formula

[0042] - Unit UD

[0043]

Chem.

[0044] (wherein

[0045]

Chem.

[0046] represents the bonding site of the monomer unit, the amount of monomer unit UA is 0 to 40 mol%, the amount of monomer unit UB is 25 to 95 mol%, the amount of monomer unit UC is 5 to 50 mol%, the amount of monomer unit UD is 0 to 25 mol%, R1 and R2 are independently hydrogen or methyl, Z1 is a bond, methyl or ethyl, Z2 is a bond, -CH2CH2O-, -CH2CH2OCH2CH2O- or -CH2CH2CH2CH2O-, R3 is -(CH2CH2O) m -R4, -(CH(CH3)CH2O) n -R4 or -(CH2CH2OCH(CH3)CH2O) y -R4, m, n and y are independently integers from 7 to 100, R4 is hydrogen or methyl, R5 is hydrogen, methyl or -CH2COOH, R6 is -OH, -OCH2OH, -OCH2CH2OH, -OCH2CH2CH2OH, -OCH2CH(CH3)CH2OH, -OCH2CH2CH2CH2OH, -NHR7, a group retaining a phosphate functional group, a group retaining a phosphonate functional group or a group retaining a sulfonate functional group, R7 is a saturated or unsaturated, straight-chain or branched-chain having 2 to 12 carbon atoms and finally one or more heteroatoms, preferably O, N or S) is a copolymer containing, The wetting agent and / or surfactant reduces the surface tension of water to less than 68 mN·m -1 The wetting agent is selected from within the group consisting of, preferably consisting of, glycol compounds and has a molecular weight of 60 g·mol -1 ~130 g·mol -1 The surfactant has a molecular weight of 131 g·mol -1 ~300 g·mol -1 and has a molecular weight of.

[0047] Component a The binder composition according to the invention contains 10% to 49% of component a by dry mass. In a preferred embodiment, the binder composition according to the invention contains 11% to 40%, preferably 15% to 30%, of component a by dry mass.

[0048] According to the invention, component a is a clinker source, a lime source or a mixture thereof. In a preferred embodiment, the clinker source is Portland clinker, Portland cement or a mixture thereof, and the lime source is lime, natural hydraulic lime or a mixture thereof.

[0049] Component b The binder composition according to the invention contains 10% to 49% of component b by dry mass. In a preferred embodiment, the binder composition according to the invention contains 11% to 40%, preferably 12% to 30%, of component b by dry mass.

[0050] According to the present invention, component b is a pozzolanic material. A pozzolanic material is a material that can react with lime or cement in the presence of water to thereby produce hydrates. In other words, a pozzolanic material is a material that enhances the hydraulic behavior of Portland cement and lime, and the hydraulic behavior is the ability to set and harden in the presence of water.

[0051] Preferably, the pozzolanic material is selected from the group consisting of, preferably consisting of, silica fume, natural pozzolan, volcanic ash, pumice, zeolitized tuff, argillized tuff, fly ash, calcined slate, metakaolin, calcined clay, especially illite, bentonite, montmorillonite, smectite, biomass ash, rice husk ash, diatomaceous earth, waste glass powder, crushed opal, carbonated basic oxygen furnace slag, carbonated olivine, carbonated wollastonite, and mixtures thereof.

[0052] Component c The binder composition according to the present invention contains 21% to 80% of component c by dry mass. In a preferred embodiment, the binder composition according to the present invention contains 30% to 70%, preferably 45% to 65% of component c by dry mass.

[0053] According to the present invention, component c is a filler, and a filler is a finely granular inorganic material and is inert. In other words, a filler cannot react with lime or cement in the presence of water and thus cannot produce hydrates.

[0054] Preferably, the filler is a limestone filler, and more preferably, the filler is a natural material (for example, calcite and its polymorphs (for example, aragonite or vaterite)) supplied from a quarry, and dolomite or precipitated calcium carbonate, and mixtures thereof.

[0055] According to the present invention, the filler is - particles of d that are 0.05 μm or more and strictly less than 8 μm in mass relative to the total mass of the filler, and 50 and - Particles in an amount of 0% to 90% by mass relative to the total mass of the filler, where d 50 is 8 μm or more and strictly less than 200 μm and is a particle mixture.

[0056] By this classification of the filler, technical effects such as reducing the viscosity of the binder composition and the concrete or industrial mortar according to the present invention and increasing the compressive strength can be obtained.

[0057] In some embodiments, the filler is - Particles in an amount of 20% to 80% by mass, preferably 25% to 50% by mass, more preferably 30% to 40% by mass relative to the total mass of the filler, where d 50 is 0.05 μm or more and strictly less than 8 μm, and - Particles in an amount of 20% to 80% by mass, preferably 30% to 70% by mass, more preferably 40% to 65% by mass relative to the total mass of the filler, where d 50 is 8 μm or more and strictly less than 200 μm and is a particle mixture.

[0058] Component d According to the present invention, the binder composition further contains at least one activator in an amount of 0.1% to 10% by dry mass relative to the total mass of components a, b, and c.

[0059] The content of the activator is determined in relation to the distribution of components a, b, and c. In other words, the dry mass percentage of the activator is determined in consideration of the fact that the total content of components a, b, and c represents 100% by dry mass.

[0060] Preferably, the activator is an alkali metal salt, an alkanolamine or a mixture thereof. Preferably, the alkali metal salt is selected from the group consisting of sodium chloride, potassium chloride, lithium chloride, sodium sulfate, potassium sulfate, lithium sulfate, sodium carbonate, potassium carbonate, lithium carbonate, sodium nitrate, potassium nitrate, lithium nitrate, sodium nitrite, potassium nitrite, lithium nitrite, calcium nitrate, calcium nitrite, sodium thiocyanate, potassium thiocyanate, lithium thiocyanate and mixtures thereof, more preferably consisting of the group thereof. Preferably, the alkanolamine is selected from the group consisting of triethanolamine (TEA), triisopropanolamine (TIPA), diethanolamine (DEA) or mixtures thereof, more preferably consisting of the group thereof. In a particularly preferred embodiment, the activator is selected from the group consisting of sodium sulfate, TIPA and mixtures thereof, more preferably consisting of the group thereof.

[0061] Component e According to the present invention, the binder composition further comprises at least one rheology enhancing admixture in a dry mass of 0.05% to 1.5% based on the total mass of component a, component b and component c.

[0062] In the context of the present invention, "rheology enhancing admixture" means a single compound or a mixture of compounds used to control the mixability, rheology and / or open time of a fresh concrete composition or wet mortar composition comprising at least a binder composition, aggregates and water.

[0063] The content of the rheology enhancing admixture is determined in relation to the proportions of component a, component b and component c. In other words, the dry mass percentage of the rheology enhancing admixture is determined taking into account that the sum of the contents of component a, component b and component c represents 100% by dry mass.

[0064] According to the present invention, the water reducing polymer (E1) has the following monomer units: - Unit UA

[0065] [Chemical formula]

[0066] - Unit UB

[0067] [Chemical formula]

[0068] - Unit UC

[0069] [Chemical formula]

[0070] - Unit UD

[0071] [Chemical formula]

[0072] (wherein,

[0073] [Chemical formula]

[0074] represents the bonding site of the monomer unit, the amount of monomer unit UA is 0 to 40 mol%, the amount of monomer unit UB is 25 to 95 mol%, the amount of monomer unit UC is 5 to 50 mol%, the amount of monomer unit UD is 0 to 25 mol%, R1 and R2 are independently hydrogen or methyl, Z1 is a bond, methyl or ethyl, Z2 is a bond, -CH2CH2O-, -CH2CH2OCH2CH2O- or -CH2CH2CH2CH2O-, R3 is -(CH2CH2O) m-R4, -(CH(CH3)CH2O) n -R4 or -(CH2CH2OCH(CH3)CH2O) y -R4, m, n, and y are independently integers from 7 to 100, R4 is hydrogen or methyl, R5 is hydrogen, methyl, or -CH2COOH, R6 is -OH, -OCH2OH, -OCH2CH2OH, -OCH2CH2CH2OH, -OCH2CH(CH3)CH2OH, -OCH2CH2CH2CH2OH, -NHR7, a group retaining a phosphate functional group, a group retaining a phosphonate functional group, or a group retaining a sulfonate functional group, R7 is a saturated or unsaturated, straight-chain or branched-chain having 2 to 12 carbon atoms and finally one or more heteroatoms, preferably O, N, or S) is a copolymer containing

[0075] In one embodiment, the total amount of monomer unit UA, the amount of monomer unit UB, the amount of monomer unit UC, and the amount of monomer unit UD is equal to 100 mol%.

[0076] In another embodiment, the water-reducing polymer (E1) contains at least another monomer unit in an amount of up to 20 mol%. Preferably, at least another monomer unit results from the polymerization of any unsaturated monomer that can copolymerize with any of the monomers contained in PCE, provided that the resulting polymer cannot be in one of the tempo ranges of the ViscoCrete® high-performance water-reducing agent manufactured by Sika®.

[0077] Preferably, the amount of monomer unit UA is 5 to 35 mol%, more preferably 10 to 30 mol%, and even more preferably 15 to 25 mol%.

[0078] Preferably, the amount of monomer unit UB is 25 to 95 mol%, more preferably 35 to 80 mol%, and even more preferably 45 to 65 mol%.

[0079] Preferably, the amount of the monomer unit UC is 5 to 50 mol%, more preferably 15 to 40 mol%, and even more preferably 20 to 30 mol%.

[0080] Preferably, the amount of the monomer unit UD is 0 to 25 mol%, more preferably 5 to 20 mol%, and even more preferably 10 to 15 mol%.

[0081] In an embodiment where the water-reducing polymer (E1) contains a phosphate functional group, at least a part of the unity of the carboxylic acid monomer is substituted with phosphate.

[0082] In an embodiment where the water-reducing polymer (E1) contains a phosphonate functional group, at least a part of the unity of the carboxylic acid monomer is substituted with phosphonate.

[0083] Preferably, the water-reducing polymer (E1) is anionic, cationic or zwitterionic.

[0084] Preferably, the water-reducing polymer has a molecular weight by mass of 5000 g·mol -1 ~300000 g·mol -1 .

[0085] In one embodiment, the water-reducing polymer (E1) is HPEG. HPEG is a copolymer derived from (meth)acrylic acid, itaconic acid monomer and ω-hydroxy-α-methallyl poly(ethylene glycol) macromonomer or ω-methoxy-α-methallyl poly(ethylene glycol).

[0086] In this embodiment, the water-reducing polymer (E1) has the following monomer units: - Unit UB

[0087]

Chemical formula

[0088] - Unit UC

[0089] [Chemical formula]

[0090] - unit UD

[0091] [Chemical formula]

[0092] (wherein

[0093] [Chemical formula]

[0094] represents the bonding site of the monomer unit, the amount of monomer unit UB is 25 to 95 mol%, the amount of monomer unit UC is 5 to 50 mol%, the amount of monomer unit UD is 0 to 25 mol%, R1 is hydrogen or methyl, R2 is hydrogen, Z1 is methyl, Z2 is a bond, R3 is -(CH2CH2O) m -R4, -(CH(CH3)CH2O) n -R4 or -(CH2CH2OCH(CH3)CH2O) y -R4, m, n and y are independently integers from 7 to 100, R4 is hydrogen or methyl, R5 is hydrogen, methyl or -CH2COOH, R6 is -OH, -OCH2OH, -OCH2CH2OH, -OCH2CH2CH2OH, -OCH2CH(CH3)CH2OH, -OCH2CH2CH2CH2OH, -NHR7, a group retaining a phosphate functional group, a group retaining a phosphonate functional group or a group retaining a sulfonate functional group, R7 is a saturated or unsaturated, straight-chain or branched-chain having 2 to 12 carbon atoms and finally one or more heteroatoms, preferably O, N or S) is a copolymer containing.

[0095] In this embodiment, preferably, the amount of the monomer unit UB is 25 to 95 mol%, more preferably 35 to 80 mol%, still more preferably 45 to 65 mol%, the amount of the monomer unit UC is 5 to 50 mol%, more preferably 15 to 40 mol%, still more preferably 20 to 30 mol%, and the amount of the monomer unit UD is 1 to 25 mol%, more preferably 5 to 20 mol%, still more preferably 10 to 15 mol%.

[0096] In another embodiment, the water-reducing polymer (E1) is APEG. APEG is a block copolymer of the A-B-A-B type (wherein the A conjugate is derived from a maleic acid monomer and the B conjugate is derived from an ω-hydroxy-α-allyl poly(ethylene glycol) macromonomer).

[0097] In this embodiment, the water-reducing polymer (E1) has the following monomer units: - Unit UA

[0098]

Chemical formula

[0099] - Unit UB

[0100]

Chemical formula

[0101] - Unit UC

[0102]

Chemical formula

[0103] - Unit UD

[0104] [Chemistry]

[0105] (wherein,

[0106] [Chemistry]

[0107] represents the bonding site of the monomer unit, the amount of monomer unit UA is 0 to 40 mol%, the amount of monomer unit UB is 25 to 95 mol%, the amount of monomer unit UC is 5 to 50 mol%, the amount of monomer unit UD is 0 to 25 mol%, R1 is hydrogen or methyl, R2 is hydrogen, Z1 is methyl, Z2 is a bond, R3 is -(CH2CH2O) m -R4, -(CH(CH3)CH2O) n -R4 or -(CH2CH2OCH(CH3)CH2O) y -R4, m, n and y are independently integers from 7 to 100, R4 is hydrogen or methyl, R5 is hydrogen, methyl or -CH2COOH, R6 is -OH, -OCH2OH, -OCH2CH2OH, -OCH2CH2CH2OH, -OCH2CH(CH3)CH2OH, -OCH2CH2CH2CH2OH, -NHR7, a group retaining a phosphate functional group, a group retaining a phosphonate functional group or a group retaining a sulfonate functional group, R7 is a saturated or unsaturated, straight-chain or branched-chain having 2 to 12 carbon atoms and finally one or more heteroatoms, preferably O, N or S) It is a copolymer containing

[0108] In this embodiment, preferably, the amount of monomer unit UA is 5 to 35 mol%, more preferably 10 to 30 mol%, still more preferably 15 to 25 mol%; preferably, the amount of monomer unit UB is 25 to 95 mol%, more preferably 35 to 80 mol%, still more preferably 45 to 65 mol%; the amount of monomer unit UC is 5 to 50 mol%, more preferably 15 to 40 mol%, still more preferably 20 to 30 mol%; and the amount of monomer unit UD is 1 to 25 mol%, more preferably 5 to 20 mol%, still more preferably 10 to 15 mol%.

[0109] In another embodiment, the water-reducing polymer (E1) is VPEG. VPEG is a vinyl ether-based PCE.

[0110] In this embodiment, the water-reducing polymer (E1) has the following monomer units: - Unit UB

[0111]

Chemical formula

[0112] - Unit UC

[0113]

Chemical formula

[0114] - Unit UD

[0115]

Chemical formula

[0116] (wherein,

[0117]

Chemical formula

[0118] represents the binding site of the monomer unit, the amount of monomer unit UB is 25 to 95 mol%, the amount of monomer unit UC is 5 to 50 mol%, the amount of monomer unit UD is 0 to 25 mol%, R1 is hydrogen or methyl, R2 is hydrogen, Z1 is a bond, Z2 is a bond, -CH2CH2O-, -CH2CH2OCH2CH2O- or -CH2CH2CH2CH2O-, R3 is -(CH2CH2O) m -R4, -(CH(CH3)CH2O) n -R4 or -(CH2CH2OCH(CH3)CH2O) y -R4, m, n and y are independently integers from 7 to 100, R4 is hydrogen or methyl, R5 is hydrogen, methyl or -CH2COOH, R6 is -OH, -OCH2OH, -OCH2CH2OH, -OCH2CH2CH2OH, -OCH2CH(CH3)CH2OH, -OCH2CH2CH2CH2OH, -NHR7, a group retaining a phosphate functional group, a group retaining a phosphonate functional group or a group retaining a sulfonate functional group, R7 is a saturated or unsaturated, straight-chain or branched-chain having 2 to 12 carbon atoms and finally one or more heteroatoms, preferably O, N or S) is a copolymer containing.

[0119] In this embodiment, preferably, the amount of monomer unit UB is 25 to 95 mol%, more preferably 35 to 80 mol%, even more preferably 45 to 65 mol%; the amount of monomer unit UC is 5 to 50 mol%, more preferably 15 to 40 mol%, even more preferably 20 to 30 mol%; and the amount of monomer unit UD is 1 to 25 mol%, more preferably 5 to 20 mol%, even more preferably 10 to 15 mol%.

[0120] In another embodiment, the water-reducing polymer (E1) is IPEG. IPEG is a copolymer derived from an acrylic acid monomer and an isoprenol poly(ethylene glycol) macromonomer.

[0121] In this embodiment, the water-reducing polymer (E1) has the following monomer units: - Unit UB

[0122]

Chemical formula

[0123] - Unit UC

[0124]

Chemical formula

[0125] - Unit UD

[0126]

Chemical formula

[0127] (wherein,

[0128]

Chemical formula

[0129] represents the bonding site of the monomer unit, The amount of the monomer unit UB is 25 to 95 mol%, The amount of the monomer unit UC is 5 to 50 mol%, The amount of the monomer unit UD is 0 to 25 mol%, R1 is hydrogen or methyl, R2 is hydrogen, Z1 is ethyl, Z2 is a bond, R3 is -(CH2CH2O) m -R4, -(CH(CH3)CH2O) n -R4 or -(CH2CH2OCH(CH3)CH2O) y -R4, m, n, and y are independently integers from 7 to 100, R4 is hydrogen or methyl, R5 is hydrogen, methyl, or -CH2COOH, R6 is -OH, -OCH2OH, -OCH2CH2OH, -OCH2CH2CH2OH, -OCH2CH(CH3)CH2OH, -OCH2CH2CH2CH2OH, -NHR7, a group retaining a phosphate functional group, a group retaining a phosphonate functional group, or a group retaining a sulfonate functional group, R7 is a saturated or unsaturated, straight-chain or branched-chain having 2 to 12 carbon atoms and finally one or more heteroatoms, preferably O, N, or S) It is a copolymer containing

[0130] In this embodiment, preferably, the amount of the monomer unit UB is 25 to 95 mol%, more preferably 35 to 80 mol%, still more preferably 45 to 65 mol%; the amount of the monomer unit UC is 5 to 50 mol%, more preferably 15 to 40 mol%, still more preferably 20 to 30 mol%; and the amount of the monomer unit UD is 1 to 25 mol%, more preferably 5 to 20 mol%, still more preferably 10 to 15 mol%.

[0131] According to the present invention, the rheology enhancer may optionally contain a wetting agent and / or a surfactant. The wetting agent and the surfactant reduce the surface tension of water to less than 68 mN.m -1 The wetting agent is selected from, preferably consisting of, the group of glycol compounds and has a molecular weight of 60 g.mol -1 ~130 g.mol -1 The surfactant has a molecular weight of 131 g.mol -1 ~300 g.mol -1

[0132] The wetting agent and the surfactant can be cationic, anionic or non-ionic, preferably non-ionic. Species that exhibit an overall neutral charge, i.e., the same number of positive and negative charges or no positive or negative charges at all, are considered non-ionic.

[0133] In a preferred embodiment, the wetting agent and the surfactant reduce the surface tension of water to less than 68 mN.m -1 The wetting agent is selected from, preferably consisting of, the group of glycol compounds and has a molecular weight of 60 g.mol -1 ~130 g.mol -1 The surfactant has a molecular weight of 131 g.mol -1 ~300 g.mol -1 The reduction in surface tension is measured by the following method: · Prepare a solution S1 of the wetting agent or the surfactant at a concentration of 0.5 g.L -1 in deionized water, · Measure the surface tension of solution S1 using the Du Noüy ring method, · Measure the surface tension of deionized water at the same temperature and pressure using the same Du Noüy ring method, · Calculate the rate of change in surface tension between deionized water and solution S1.

[0134] ​In a preferred embodiment, the wetting agent is selected from the group consisting of, preferably consisting of, 2-methyl-2,4-pentanediol (MPD), diethylene glycol (DEG), neopentyl glycol (NPG) and mixtures thereof.

[0135] In a preferred embodiment, the surfactant can be 2,4,7,9-tetramethyldec-5-yn-4,7-diol.

[0136] Dry concrete composition or industrial dry mortar composition The present invention also relates to a dry concrete composition or an industrial dry mortar composition comprising at least one aggregate and the binder composition described above, particularly tile adhesives, coatings, assembly mortars, repair mortars, primers, technical mortars and floor finishing mortars. The dry concrete or industrial mortar composition may ultimately contain other admixtures and additives.

[0137] According to the present invention, a "dry" concrete composition or an industrial "dry" mortar composition refers to a composition in powder form that is ready to be mixed with water. In other words, the dry concrete composition or industrial dry mortar composition of the present invention may contain some moisture, but essentially contains solid components that are intended to be mixed with water before its application.

[0138] The aggregates include the major categories of particulate materials used in the construction industry, including sand, gravel, crushed stone, slag (not granular), recycled concrete and geosynthetic aggregates. These function as reinforcing materials that impart strength to the entire composite material.

[0139] Advantageously, the dry concrete composition or industrial dry mortar composition can also contain, apart from the aggregates, one or several components, in particular functional admixtures, additives and fibers which may be other optional components as described hereinafter.

[0140] Other optional components The binder composition is advantageously fortified with one or several other components which are in particular functional additives, preferably components selected from the following list.

[0141] · Water retention agent. The water retention agent has the property of retaining the mixing water before coagulation. Therefore, the water is trapped in the wet compound paste, improving its binding. To a certain extent, the water is less likely to be absorbed by the support.

[0142] The water retention agent is preferably selected from the group comprising modified cellulose, modified guar, modified cellulose ethers and / or guar ethers and mixtures thereof, more preferably from the group consisting of methyl cellulose, methyl hydroxypropyl cellulose, methyl hydroxyethyl - cellulose and mixtures thereof.

[0143] · Rheology agent Possible rheology agents (also named "thickeners") are preferably selected from the group comprising starch ethers, cellulose ethers and / or gums (such as welan guar xanthan, succinoglycan), modified polysaccharides - preferably among others processed starch ethers, polyvinyl alcohol, polyacrylamide, sepiolite, and mixtures thereof, more preferably from the group consisting of them.

[0144] · Defoaming agent / antifoaming agent Possible defoaming agents are preferably selected from the group comprising polyether polyols and mixtures thereof, more preferably from the group consisting of them.

[0145] · Biocide Possible biocides are preferably selected from the group comprising mineral oxides such as zinc oxide and mixtures thereof, more preferably from the group consisting of them.

[0146] · Pigment Possible pigments are preferably selected from the group comprising TiO2, iron oxide and mixtures thereof, more preferably from the group consisting of them.

[0147] · Flame retardant A flame retardant (or fire retardant) enables to enhance the fire resistance and / or reduce the rate of spread of combustion of a composition.

[0148] · Air entraining agent An air entraining agent (surfactant) is preferably selected from the group consisting of, more preferably consisting of, preferably the group consisting of, more preferably consisting of, more preferably the group consisting of natural resins, sulfuric acid compounds and sulfonic acid compounds, synthetic detergents, organic fatty acids and mixtures thereof, more preferably lignosulfonic acid, basic fatty acid soaps and mixtures thereof, more preferably the group consisting of olefin sulfonates, sodium lauryl sulfate and mixtures thereof, more preferably consisting of them.

[0149] · Retarder A retarder is preferably selected from the group consisting of tartaric acid and its salts, sodium or potassium salts, citric acid and its salts, sodium (trisodium citrate) and mixtures thereof, more preferably consisting of them.

[0150] Furthermore, other components may be · Plasticizer · Fiber · Dispersion powder · Polymer resin · Complexing agent · Polyol-based drying shrinkage reducing agent and can be.

[0151] The total content of these other optional components in the dry concrete composition or industrial dry mortar composition is preferably 0.1% to 10% by mass of the total mass of the dry concrete composition or industrial dry mortar composition.

[0152] Fresh concrete composition or industrial wet mortar composition The present invention also relates to a fresh concrete composition or an industrial wet mortar composition comprising at least one aggregate, the binder composition described above and water, in particular tile adhesives, coatings, assembly mortar, repair mortar, primers, technical mortar and floor finishing mortar.

[0153] In certain embodiments, the wet mortar composition is a so-called "ready-to-use" mortar. "Ready-to-use" mortars are used for assembling bricks or blocks at a construction site. These are obtained by directly mixing all the elements of the composition (binder, aggregate and other components) with water in a mixing plant. This includes a set retarding agent, which allows for transport and delayed use for several days while maintaining its rheological and hardening properties.

[0154] Method for preparing a fresh concrete composition or a wet mortar composition The present invention also relates to a method for preparing the above-mentioned fresh concrete composition or industrial wet mortar composition, comprising the step of mixing water, at least one aggregate and the binder composition described above, wherein the binder composition is prepared separately and / or in the form of a premix from at least some of the different components of the binder composition before or during the mixing step.

[0155] In other words, the fresh concrete composition or the industrial wet mortar composition can be prepared by two separate methods.

[0156] In the first method, the binder composition is prepared and then mixed with at least one aggregate. The dry concrete composition or dry mortar composition is then mixed with water.

[0157] In the second method, the fresh concrete composition or industrial wet mortar composition is prepared by mixing each component of the binder composition and the aggregate in water.

[0158] According to the present disclosure, the term "mixing" should be understood as any form of mixing.

[0159] In a preferred embodiment, part of the binder composition and at least part of the water are mixed together before being mixed with the aggregate.

[0160] In a preferred embodiment, this method is carried out with a ratio of water to the binder composition of 0.1 to 0.5, preferably 0.15 to 0.45, more preferably 0.2 to 0.4.

[0161] Hardened concrete composition or hardened industrial mortar composition The present invention also relates to a hardened concrete composition or a hardened industrial mortar composition obtained from the above-described fresh concrete composition or industrial wet mortar composition.

[0162] Use of the binder composition The present invention also relates to the use of the above-described binder composition for improving the rheology of a fresh concrete composition or an industrial wet mortar composition, particularly in the fresh state of tile adhesives, coatings, assembly mortars, repair mortars, primers, technical mortars and floor finishing mortars, for example the yield stress in the fresh state and the viscosity in the fresh state.

[0163] Advantageously, for the use according to the invention, the yield stress of the mortar in the fresh state is 0 Pa to 200 Pa, preferably 5 Pa to 100 Pa, more preferably 30 Pa to 60 Pa.

[0164] Advantageously, for the use according to the invention, the viscosity of the paste in the fresh state is 0 Pa·s to 50 Pa·s, preferably 15 Pa·s to 35 Pa·s, more preferably 20 Pa·s to 30 Pa·s.

[0165] The present invention also relates to the use of the above-described binder composition for the preparation of precast concrete or ready-mixed concrete.

Examples

[0166] (Example 1) Synergistic effect of Na2SO4 and TIPA on mechanical properties The weight ratios of the binder, component a, component b, and component c of the aggregate were set to 2.42, and ten types of mortars were prepared using the aggregate according to NF EN standard 196-1. The obtained compressive strengths, determined according to the composition and NF EN 196-1, are listed in Table 1 below.

[0167] [Table 1]

[0168] As can be seen from Table 1, the compressive strength of the mortar is greatly affected by the type and combination of the activator.

[0169] When Na2SO4 and TIPA are added in combination, especially when the content of TIPA is 0.5% with respect to component a, component b, and component c, and similarly when the content of Na2SO4 is set to either 1% (M6) or 2% (M10), similar strength gains are observed at all ages.

[0170] Therefore, by appropriately selecting the activator, it is possible to improve the performance of the binder and the resulting mortar.

[0171] (Example 2) Effect of the pozzolan source Six additional mortars were prepared according to the same protocol as described in Example 1, in accordance with NF EN standard 196-1. The composition and compressive strength are listed in Table 2 below. Mortars M1 and M6 are redisplayed in Table 2.

[0172] [Table 2]

[0173] As can be seen from Table 2, the compressive strength of the mortar is significantly affected by the pozzolan source evaluated on the 28th day regardless of the presence or absence of the activator, which is the same on the 1st day, emphasizing that the reactivity of Portland cement is dominant at the 1st day stage.

[0174] Therefore, combining Na2SO4 and TIPA at the selected dosages enables the improvement of mechanical properties at early ages, and the long-term (28-day) performance is at least the same.

[0175] (Example 3) Rheological influence of the specific limestone filler Using a third source of natural pozzolan, four additional mortars were prepared according to the protocol described above. The composition, spread characteristics and mechanical properties of the mortar are described in Table 3 below.

[0176]

Table 3

[0177] Gradual replacement of the coarse limestone filler from 0.1% to 0.075% enables a significant reduction of the rheology enhancer (component e), while equal rheology measured by the spread of the mortar is maintained.

[0178] Note that in this case, gradual replacement of the coarse limestone filler with the fine limestone filler did not affect the final mechanical properties of the mortar.

[0179] (Example 4) Influence of the wetting agent on rheology and mechanical properties Using a fourth source of natural pozzolan, three additional mortars were prepared according to the protocol described in Example 1. The composition, rheology characteristics (yield stress and viscosity) and mechanical properties are described in Table 4 below.

[0180]

Table 4

[0181] As can be confirmed from Table 4, when methylpentanediol is added as a wetting agent, it becomes possible to reduce both the yield stress and the viscosity, while the compressive strength is maintained on the first and 28th days. Since the mortar containing the wetting agent is easier to handle than the mortar without the wetting agent, this is an additional technical effect that benefits the workers.

Claims

1. a. 10% to 49% by dry mass of clinker source, lime source, or mixture thereof b. At least one pozzolanic material, comprising 10% to 49% by dry mass. c. At least one filler, comprising 21% to 80% by dry mass. d. At least one activator in an amount of 0.1% to 10% by dry mass relative to the total mass of components a, b, and c. e. At least one rheologically strengthening admixture in an amount of 0.05% to 1.5% by dry mass relative to the total mass of components a, b, and c. A binder composition comprising, The aforementioned filler, - 10% to 100% by mass relative to the total mass of the filler, d 50 Particles that are 0.05 μm or larger and strictly less than 8 μm, and - 0% to 90% by mass relative to the total mass of the filler, d 50 Particles that are 8 μm or larger but strictly less than 200 μm. It is a particle mixture, Rheologically strengthening admixtures (E1) Contains at least one water-reducing polymer, (E2) Optionally, it may contain a wetting agent and / or a surfactant. The water-reducing polymer (E1) is polyethylene glycol and / or monomer units that retain terminal phosphonate groups: - Unit UA 【Chemistry 1】 - Unit UB 【Chemistry 2】 - Unit UC 【Transformation 3】 - Unit UD 【Chemistry 4】 (In the formula, 【Transformation 5】 This represents the binding site of the monomer unit, The amount of monomer unit UA is 0 to 40 mol%, The amount of monomer unit UB is 25-95 mol%, The amount of monomer unit UC is 5 to 50 mol%, The amount of monomer unit UD is 0 to 25 mol%, R 1 and R 2 These are independently hydrogen or methyl, Z 1 The bond is methyl or ethyl, Z 2 is a bond, -CH 2 CH 2 O-, -CH 2 CH 2 OCH 2 CH 2 O- or -CH 2 CH 2 CH 2 CH 2 O- and R 3 is, -(CH 2 CH 2 O) m -R 4 ,-(CH(CH 3 )CH 2 O) n -R 4 or -(CH 2 CH 2 OCH(CH 3 )CH 2 O) y -R 4 And, m, n, and y are independent integers between 7 and 100. R 4 is hydrogen or methyl, R 5 is hydrogen, methyl or -CH 2 COOH R 6 -OH, -OCH 2 OH, -OCH 2 CH 2 OH, -OCH 2 CH 2 CH 2 OH, -OCH 2 CH(CH 3 )CH 2 OH, -OCH 2 CH 2 CH 2 CH 2 OH, -NHR 7 , a group that retains a phosphate functional group, a group that retains a phosphonate functional group, or a group that retains a sulfonate functional group, R 7 (These are saturated or unsaturated, linear or branched chains containing 2 to 12 carbon atoms and ultimately one or more heteroatoms, preferably O, N, or S.) It is a copolymer containing, The wetting agent and / or surfactant reduces the surface tension of water to 68 mN.m -1 The concentration is reduced to less than 60 g.mol, and the wetting agent is selected from the group containing glycol compounds, preferably from the group consisting of them. -1 ~130g.mol -1 It has a molecular weight of 131 g.mol, and the surfactant is 131 g.mol. -1 ~300g.mol -1 Having a molecular weight of, Binder composition.

2. The binder composition according to claim 1, wherein the pozzolanic material is selected from the group comprising silica fume, natural pozzolanic material, volcanic ash, pumice, zeolitized tuff, clayey tuff, fly ash, calcined schist, metakaolin, calcined clay, particularly illite, bentonite, montmorillonite, smectite, biomass ash, rice husk ash, diatomaceous earth, waste glass powder, crushed opal, carbonated basic oxygen converter slag, carbonated olivine, carbonated wollastonite, and mixtures thereof, preferably from the group comprising them.

3. The binder composition according to claim 1, wherein the filler is limestone filler, more preferably natural material supplied from a quarry (e.g., calcite and its polymorphs (e.g., aragonite or vaterite)), and dolomite or precipitated calcium carbonate or mixtures thereof.

4. The binder composition according to claim 1, wherein the activator is an alkali metal salt, an alkanolamine, or a mixture thereof, preferably the alkali metal salt is selected from the group comprising sodium chloride, potassium chloride, lithium chloride, sodium sulfate, potassium sulfate, lithium sulfate, sodium carbonate, potassium carbonate, lithium carbonate, sodium nitrate, potassium nitrate, lithium nitrate, sodium nitrite, potassium nitrite, lithium nitrite, calcium nitrate, calcium nitrite, sodium thiocyanate, potassium thiocyanate, lithium thiocyanate, and mixtures thereof, more preferably the group comprising them, and preferably the alkanolamine is selected from the group comprising triethanolamine (TEA), triisopropanolamine (TIPA), diethanolamine (DEA), or a mixture thereof, more preferably the group comprising them.

5. A dry concrete composition or industrial dry mortar composition comprising at least one aggregate and the binder composition according to any one of claims 1 to 4, particularly a tile adhesive, coating, assembly mortar, repair mortar, primer, technical mortar and floor finishing mortar.

6. A ready-mix concrete composition or industrial wet mortar composition comprising at least one aggregate, the binder composition according to any one of claims 1 to 4, and water, particularly a tile adhesive, coating, assembly mortar, repair mortar, primer, technical mortar, and floor finishing mortar.

7. A hardened concrete composition or a hardened industrial mortar composition obtained from the ready-mixed concrete composition or industrial wet mortar composition described in claim 6.

8. A method for preparing a ready-mix concrete composition or an industrial wet mortar composition according to claim 6, comprising the step of mixing water, at least one aggregate and a binder composition according to any one of claims 1 to 4, wherein the binder composition is prepared separately and / or in the form of a premix from at least some of the different components of the binder composition before the mixing step or in situ during the mixing step.

9. The method according to claim 8, wherein the ratio of water to the binder composition is 0.1 to 0.5, preferably 0.15 to 0.45, and more preferably 0.2 to 0.

4.

10. Use of a binder composition according to any one of claims 1 to 4 for improving the fresh-state rheology, such as the fresh-state yield stress and fresh-state viscosity, of a ready-mix concrete composition or an industrial wet mortar composition, particularly tile adhesives, coatings, assembly mortars, repair mortars, primers, technical mortars and floor finishing mortars.

11. Use of the binder composition according to any one of claims 1 to 4, wherein the yield stress in the fresh state is 0 Pa to 200 Pa, preferably 5 Pa to 100 Pa, and more preferably 30 Pa to 60 Pa.

12. Use of the binder composition according to any one of claims 1 to 4, wherein the viscosity of the paste in its fresh state is 0 Pa.s to 50 Pa.s, preferably 15 Pa.s to 35 Pa.s, and more preferably 20 Pa.s to 30 Pa.s.

13. Use of the binder composition according to any one of claims 1 to 4 for the preparation of precast concrete or ready-mixed concrete.

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