Hydraulic binder composition for floor application

Abstract

The present invention comprises a hydraulic binder composition including the following: Component a) Portland cement in an amount between 0.5% by mass and 5% by mass, Component b) Aluminate cement between 5% by mass and 30% by mass, Component c) Sulfate source between 5% by mass and 15% by mass, Component d) is between 35% by mass and 88.5% by mass, and is between 7.5 μm and 12 μm. 50 and d between 19 μm and 29 μm 85 A blast furnace slag fine powder having the following properties.

Description

[Technical Field]

[0001] This disclosure relates to the field of hydraulic binder compositions comprising blast furnace slag powder (GGBS) for the preparation of industrial mortars. In particular, the technical field of the present invention relates to hydraulic mineral binders comprising blast furnace slag powder (GGBS or slag) used in compositions that can solidify and harden, such as mortars for floor applications such as self-leveling underlayment (SLU) and screed. [Background technology]

[0002] To be suitable for use on floors, mortar must harden and dry quickly. In fact, floor products such as SLU and screed are intended to be covered with floor covering products such as tiles or wooden flooring, and workers should be able to walk on the floor while pursuing construction or renovation. Furthermore, the moisture content should be low in order to be covered with floor covering products.

[0003] Furthermore, floor products require heat resistance, especially when an underfloor heating system is present.

[0004] To the best of the applicant's knowledge, industrial mortars for commercial use in flooring contain Portland cement as a binder, combined with rapid cements such as aluminate cement and sulfoaluminate cement, and a calcium sulfate source that meets the requirements for rapid hardening and rapid drying.

[0005] Even if these industrial mortars provide satisfaction, controlling carbon dioxide emissions remains a major challenge. For example, the production of Portland cement has a strong negative impact on the environment due to the large amount of carbon dioxide emitted. Cement production inherently generates CO2 through the decarboxylation reaction of limestone while the raw materials are fired at very high temperatures (1450°C) in a kiln (Equation (1)). CaCO3(s)→CaO(s)+CO2(g) (formula.(1))

[0006] Furthermore, carbon dioxide is emitted from the combustion of fossil fuels required to heat the cement kilns. When additional emissions from grinding are added, almost one ton of CO2 is produced per ton of Portland cement. Overall, the cement industry accounts for approximately 7-9% of global carbon dioxide emissions.

[0007] Hydraulic binder compositions with low carbon content have been developed, for example, by replacing at least some Portland cement with blast furnace slag powder (GGBS), as disclosed in literature WO2017 / 198930 or WO2019 / 110134. [Overview of the Initiative] [Problems that the invention aims to solve]

[0008] However, in the field of industrial mortar for floor applications, while quick drying is achieved by the aluminate cement portion, this also generates carbon dioxide emissions. Therefore, there is a need to develop industrial mortar for floor applications in which Portland cement and aluminate cement are replaced, at least partially, with binders that have a lower carbon dioxide impact.

[0009] In this specification, the present invention aims to address at least one of the above-mentioned problems and / or needs by achieving at least one of the following objectives: -O1- Provides a GGBS-based binder or a mortar composition comprising the GGBS-based binder, which is an attractive alternative to ordinary Portland cement (OPC) and allows for a reduction in the use of aluminate cement bases in floor compositions. To provide a mortar composition comprising an O2- slag-based binder or the GGBS-based binder, which is environmentally friendly. To provide a mortar composition comprising an O3- slag-based binder or the GGBS-based binder, which produces a wet formulation with suitable rheological properties, i.e., a wet formulation with stable rheology (excellent workability) during the normal solidification time (e.g., several minutes to several hours) required by the user of the wet formulation. [Means for solving the problem]

[0010] Component a) Portland cement in an amount between 0.5% by mass and 5% by mass, Component b) Aluminate cement between 5% by mass and 30% by mass, Component c) A sulfate source between 5% by mass and 15% by mass, Component d) is between 35% by mass and 88.5% by mass, and is between 7.5 μm and 12 μm. 50 and d between 19 μm and 29 μm 85 blast furnace slag fine powder A hydraulic binder composition containing [the specified element] achieved at least one of the above objectives.

[0011] The present invention also relates to a dry industrial mortar composition comprising at least one aggregate and the hydraulic binder composition described above, particularly a mortar for application to floors, especially a screed and a self-leveling underlayment (SLU).

[0012] The present invention also relates to a wet industrial mortar formulation, particularly a mortar for floor covering, and especially a self-leveling underlayment (SLU), comprising at least one aggregate, the hydraulic binder composition described above, and water.

[0013] The present invention further relates to a hardened industrial mortar product obtained from the wet industrial mortar formulation described above.

[0014] The present invention further relates to a method for preparing the above-described wet industrial mortar formulation, which includes a step of mixing water, at least one aggregate, and the above-described hydraulic binder composition, and the hydraulic binder composition is prepared in situ, either before or during the mixing step, from at least some of the different components of the separately made hydraulic binder composition and / or in the form of a premix.

[0015] According to the terms used herein, the following non-limiting definitions must be considered.

[0016] "Binder" refers to a "hydraulic binder", which means any substance that hardens by simply adding water, such as cement.

[0017] "Cement" is understood to mean a powdery substance made for use in the manufacture of mortar or concrete. They are mineral binders and may contain no organic compounds. It refers to any ordinary cement, which includes mixtures of ordinary Portland cement, ordinary Portland cement, pozzolanic substances and / or fillers, and alkali-activated-based cement.

[0018] "Clinker" is understood as the main constituent phase of ordinary Portland cement obtained from the co-firing of limestone and aluminosilicate sources.

[0019] "Mortar" refers to a substance composed of a binder, aggregates such as fillers, sand, and other components such as admixtures.

[0020] "Dry industrial mortar composition" refers to a substance composed of a binder, aggregates such as sand and gravel, and other components such as admixtures.

[0021] "Wet industrial mortar formulation" refers to a substance composed of a binder, aggregates such as sand and gravel, and other components such as admixtures and water.

[0022] "Hardened industrial mortar product" refers to the hardened product obtained from a wet industrial mortar composition after reaction and evaporation of water.

[0023] "d 10 " gives the size of the median in the particle size distribution of a substance (usually in micrometers for cementitious materials). This means that 10% of the particles have a size less than the d 10 value, and 90% of the particles have a size greater than the d 10 value. The measurement of d 10 is carried out by laser diffraction analysis, which is also known as laser diffraction spectroscopy, and is performed by a dry method using a laser diffraction analyzer such as "SYMPATEC" commercialized by SYMPATEC.

[0024] "d 50 " gives the size of the median in the particle size distribution of a substance (usually in micrometers for cementitious materials). This means that 50% of the particles have a size less than the d 50 value, and 50% of the particles have a size greater than the d 50 value. The measurement of d 50 is carried out by laser diffraction analysis, which is also known as laser diffraction spectroscopy, and is performed by a dry method using a laser diffraction analyzer such as "SYMPATEC" commercialized by SYMPATEC.

[0025] "d 85 " gives the size of the median in the particle size distribution of a substance (usually in micrometers for cementitious materials). This means that 85% of the particles have a size less than the d 85 value, and 15% of the particles have a size greater than the d 85 value. The measurement of d 85 is carried out by laser diffraction analysis, which is also known as laser diffraction spectroscopy, and is performed by a dry method using a laser diffraction analyzer such as "SYMPATEC" commercialized by SYMPATEC.

[0026] "d 90This gives the median size of the particle size distribution of the material (usually in micrometers for cement materials). This means that 90% of the particles are d 90 Having a size less than the value, 10% of the particles are d 90 This means it has a magnitude exceeding the value. 90 The measurement is performed by laser diffraction analysis, also known as laser diffraction spectroscopy, using a dry method with a laser diffraction analyzer such as "SYMPATEC," which is commercialized by SYMPATEC Corporation. [Brief explanation of the drawing]

[0027] [Figure 1] Figure 1 is a graph showing the particle size distribution of GGBS used in the hydraulic binder of the present invention. [Modes for carrying out the invention]

[0028] Hydraulic binder composition As described above, in the first embodiment, the present invention relates to a hydraulic binder composition, Component a) Portland cement in an amount between 0.5% by mass and 5% by mass, Component b) Aluminate cement between 5% by mass and 30% by mass, Component c) A sulfate source between 5% by mass and 15% by mass, Component d) is between 35% by mass and 88.5% by mass, and is between 7.5 μm and 12 μm. 50 and d between 19 μm and 29 μm 85 blast furnace slag fine powder This is a hydraulic binder composition containing [a specific substance].

[0029] Portland cement The hydraulic binder composition according to the present invention comprises component a), which is Portland cement in an amount between 0.5% by mass and 5% by mass.

[0030] In one embodiment, according to standard EN 197-1, Portland cement is ordinary Portland cement (OPC).

[0031] Advantageously, the hydraulic binder composition contains Portland cement in an amount between 1% by mass and 4% by mass, preferably between 1.5% by mass and 3.5% by mass, and more preferably between 2% by mass and 3% by mass.

[0032] Aluminate cement The hydraulic binder composition according to the present invention comprises component b) which is aluminate cement in an amount between 5% and 30% by mass. Preferably, the aluminate cement is selected from the group comprising calcium aluminate cement (CAC), calcium sulfoaluminate cement (CSA), Belite-Ye'elimite-Ferritecement (BYF), and mixtures thereof, preferably from the group comprising these.

[0033] Calcium aluminate cement may consist of at least one of the following crystalline structures: monocalcium aluminate (CaO.Al2O3), monocalcium diaryluminate (CaO.2 Al2O3), monocalcium hexaaluminate (CaO.6 Al2O3), dicalcium aluminosilicate (2 CaO.Al2O3.SiO2), tricalcium aluminate (3 CaO.Al2O3), dodecacalcium heptaaluminate (12 CaO.7 Al2O3), ye'elimite (4 CaO.3 Al2O3.SO3), calcium aluminoferrite (4 CaO.Al2O3.Fe2O3).

[0034] Advantageously, the hydraulic binder composition contains aluminate cement in an amount between 7.5% by mass and 25% by mass, preferably between 10% by mass and 20% by mass, and more preferably between 12.5% ​​by mass and 17.5% by mass.

[0035] Sulfate source The hydraulic binder composition according to the present invention comprises component c), which is a sulfate source in an amount between 5% by mass and 15% by mass.

[0036] Preferably, the sulfate source is selected from the group comprising calcium sulfate (CaSO4), sodium sulfate (Na2SO4), potassium sulfate (K2SO4), lithium sulfate (Li2SO4), and mixtures thereof, preferably from the group consisting of these.

[0037] When the sulfate source is calcium sulfate, it may be anhydrite, hemihydrate, or dihydrate, the difference being the water molecules bound to the calcium sulfate. Anhydrite contains no water (CaSO4), hemihydrate contains half a water molecule (CaSO4.1 / 2 H2O), and dihydrate, also known as gypsum, contains two water molecules (CaSO4.2 H2O). According to the present invention, calcium sulfate is anhydrous (anhydrite) calcium sulfate.

[0038] Advantageously, the hydraulic binder composition contains a sulfate source between 8% and 12% by mass, preferably between 9% and 11% by mass.

[0039] Blast furnace slag fine powder The hydraulic binder composition according to the present invention has a particle size between 7.5 μm and 12 μm. 50 and d between 19 μm and 29 μm 85 The blast furnace slag fine powder contains component d) in an amount between 35% and 88.5% by mass.

[0040] Advantageously, the hydraulic binder composition contains component d) in an amount between 50% and 80% by mass, preferably between 60% and 75% by mass.

[0041] In one embodiment, the blast furnace slag fine powder according to the present invention is between 0.5 μm and 1.7 μm. 10 It has.

[0042] In one preferred embodiment, the blast furnace slag fine powder is between 25 μm and 32 μm. 90 It also possesses.

[0043] In one embodiment, the blast furnace slag fine powder is between 8 μm and 10 μm. 50 It has.

[0044] In one embodiment, the blast furnace slag fine powder is between 21 μm and 25 μm. 85 It has.

[0045] In one embodiment, the blast furnace slag fine powder is between 27 μm and 30 μm. 90 It has.

[0046] Dry industrial mortar composition As described above, in a second embodiment, the present invention relates to a dry industrial mortar composition comprising at least one aggregate and the hydraulic binder composition described above, in particular to mortar for application to floors, in particular to screed and self-leveling underlayment (SLU).

[0047] According to the present invention, a “dry” concrete composition or “dry” industrial mortar composition refers to a composition that is in powder form and ready to be mixed with water. In other words, the dry concrete composition or dry industrial mortar composition of the present invention may contain some moisture, but essentially contains solid components intended to be mixed with water before application.

[0048] Aggregates fall under the broad category of particulate materials used in construction and include fillers, sand, gravel, crushed stone, slag (not granular), recycled concrete, and geosynthetic aggregates. They function as reinforcing materials that add strength to the overall composite material.

[0049] Advantageously, the dry concrete composition or dry industrial mortar composition may also contain one or more components in addition to aggregate, particularly functional admixtures, additives, and fibers, which may be any other components described later.

[0050] any other ingredients The binder composition is preferably advantageously enhanced with one or more other components, in particular functional additives, which are components selected from the following list.

[0051] Water-retaining agent The water-retaining agent has the property of retaining water mixed before solidification. Because the water is trapped within the wet compounding paste, its bonding is improved. The support reduces, to a certain extent, the amount of water absorbed.

[0052] The water-retaining agent is preferably selected from the group comprising modified cellulose, modified guar, modified cellulose ether and / or guar ether and mixtures thereof, and more preferably from the group comprising methylcellulose, methylhydroxypropylcellulose, methylhydroxyethylcellulose and mixtures thereof.

[0053] Rheological agents Possible rheological agents (also called "thickeners") are preferably selected from the group comprising, more preferably from, the group comprising starch ethers, cellulose ethers and / or rubbers (e.g., welan guar xanthane, succinoglycans), modified polysaccharides (preferably among modified starch ethers), polyvinyl alcohol, polyacrylamide, sepiolite and mixtures thereof.

[0054] Antifoaming agent / bubble inhibitor Possible defoaming agents are preferably selected from the group comprising polyether polyols and mixtures thereof, more preferably from the group comprising them.

[0055] biocides Possible biocides are preferably selected from the group comprising mineral oxides such as zinc oxide and mixtures thereof, more preferably from the group comprising them.

[0056] pigment Possible pigments are preferably selected from the group comprising TiO2, iron oxide, and mixtures thereof, more preferably from the group comprising them.

[0057] Flame retardant Flame retardants (or fire retardants) make it possible to increase the fire resistance of a composition and / or reduce the rate of flame spread.

[0058] Air-entraining agent The air-entraining agent (surfactant) is advantageously selected from the group comprising natural resins, sulfate compounds or sulfonate compounds, synthetic detergents, organic fatty acids and mixtures thereof, more preferably from the group comprising lignosulfonates, fatty acid-based soaps and mixtures thereof, more preferably from the group comprising sulfonate olefins, sodium lauryl sulfate and mixtures thereof, more preferably from the group comprising these.

[0059] Delaying agent The retarder is advantageously selected from the group comprising tartaric acid and its salts, sodium salts or potassium salts, citric acid and its salts, sodium (trisodium citrate) and mixtures thereof, more preferably from the group comprising these.

[0060] Accelerator The accelerator is advantageously selected from the group comprising alkali metal salts, more preferably from the group comprising sodium carbonate and potassium carbonate, sodium chloride, or calcium formate or lithium salts.

[0061] Furthermore, the following other ingredients may be used: • Plasticizer ·fiber ·Dispersion powder ·Polymer resin • Complexing agent • Polyol-based drying shrinkage reducer.

[0062] The total content of any other components in the dry concrete composition or dry industrial mortar composition is preferably between 0.1% by mass and 10% by mass of the total mass of the dry concrete composition or dry industrial mortar composition.

[0063] Wet industrial mortar formulations As described above, in a third embodiment, the present invention relates to a wet industrial mortar formulation, in particular a mortar for floor covering, in particular a self-leveling underlayment (SLU), comprising at least one aggregate, the hydraulic binder composition described above, and water.

[0064] Hardened industrial mortar products As described above, the present invention relates in a fourth embodiment to a hardened industrial mortar product obtained from the wet industrial mortar formulation described above.

[0065] The wet industrial mortar mixture is applied and allowed to dry and harden.

[0066] Method for preparing wet industrial mortar formulations As described above, in a fifth aspect of the present invention, the present invention relates to a method for preparing the above-described wet industrial mortar formulation, comprising the step of mixing water, at least one aggregate and the above-described hydraulic binder composition, wherein the hydraulic binder composition is prepared in situ before or during the mixing step from at least some of the different components of the hydraulic binder composition and / or in the form of a premix.

[0067] In other words, a wet concrete composition or a wet industrial mortar composition can be prepared by two different methods.

[0068] In the first method, a binder composition is prepared and then mixed with at least one aggregate. Subsequently, the dry concrete composition or dry mortar composition is mixed with water.

[0069] In the second method, a wet concrete composition or a wet industrial mortar composition is prepared by mixing the binder composition and the aggregate components in water.

[0070] According to this disclosure, the term “mixture” should be understood as any form of mixture.

[0071] In a preferred embodiment, a portion of the binder composition and at least a portion of the water are mixed together before mixing with the aggregate.

[0072] In a preferred embodiment, the method is carried out with a water-to-binder composition ratio between 0.1 and 1.2, preferably between 0.15 and 0.45, and more preferably between 0.2 and 0.4.

[0073] Use of hydraulic binder composition The present invention also relates to the use of the above-mentioned binder composition to improve the fresh-state rheology, such as the fresh-state yield stress and fresh-state viscosity, of wet industrial mortar compositions, particularly for floor covers.

[0074] Advantageously, for use according to the present invention, the yield strength of the mortar in its fresh state is set between 0 Pa and 200 Pa, preferably between 5 Pa and 100 Pa, and more preferably between 30 Pa and 60 Pa.

[0075] Advantageously, for use according to the present invention, the viscosity of the paste in its fresh state is set between 0 Pa.s and 50 Pa.s, preferably between 15 Pa.s and 35 Pa.s, and more preferably between 20 Pa.s and 30 Pa.s. [Examples]

[0076] Example 1: Preparation of a hydraulic binder composition and mortar containing the same according to the present invention The hydraulic binder composition was prepared by mixing its different components. The components and their proportions are listed in Table 1 below.

[0077] [Table 1]

[0078] The GGBS used has the particle size distribution shown in Figure 1.

[0079] Subsequently, this hydraulic binder composition was mixed with sand and filler in a ratio of 52.39% dry mass of hydraulic binder and 47.61% dry mass of sand. The resulting mixture was then mixed with water at a water-to-binder ratio of 0.34.

[0080] Example 2: Adhesion test and shrinkage test The mortar obtained in Example 1 was stored for 28 days at 23°C and 50% relative humidity. Adhesion resistance and shrinkage were measured according to standard NF EN 13813. The measured adhesion strength was equal to 1.07 MPa, which is higher than the specified 1 MPa according to CSTB (Centre Scientifique et Technique du Batiment) document QB11-02 (https: / / evaluation.cstb.fr / doc / certification / certificats / qb11-02 / qb11-02-document-technique-11-02-enduits-de-sol-rev01-140322.pdf) published on March 14, 2022. Shrinkage was -50 μm / m, which is very low according to the standard and technical recommendations.

[0081] Example 3: Change in the ratio of water to binder A hydraulic binder was prepared in the same manner as in Example 1, except that the ratio of water to binder was 0.43. The adhesive resistance was measured according to standard NF EN 13813. The measured adhesive strength was equal to 1.03 MPa.

[0082] Example 4: Changes in adhesive strength under different storage conditions In accordance with CSTB document QB11-02, published on March 14, 2022, the mortar obtained in Example 1 was stored for 28 days on a wet support or under moisture recovery conditions at 45°C and 60°C. Under these conditions, the specification was set to a level of 0.8 MPa. The resulting adhesive strength is reported in Table 2 below.

[0083] [Table 2]

[0084] Table 2 shows that all adhesive strengths exceed the 0.8 MPa specification recommended in CSTB document QB11-02, published on March 14, 2022.

Claims

1. A hydraulic binder composition, Component a) Portland cement in an amount between 0.5% by mass and 5% by mass, Component b) Aluminate cement in an amount between 5% by mass and 30% by mass, Component c) A sulfate source in an amount between 5% by mass and 15% by mass, Component d) is between 35% by mass and 88.5% by mass, and is between 7.5 μm and 12 μm. ５０ and d is between 19 μm and 29 μm ８５ blast furnace slag fine powder A hydraulic binder composition containing [a specific substance].

2. The hydraulic binder composition according to claim 1, comprising Portland cement in an amount between 1% by mass and 4% by mass, preferably between 1.5% by mass and 3.5% by mass, and more preferably between 2% by mass and 3% by mass.

3. The hydraulic binder composition according to claim 1 or 2, comprising aluminate cement in an amount between 7.5% by mass and 25% by mass, preferably between 10% by mass and 20% by mass, and more preferably between 12.5% ​​by mass and 17.5% by mass.

4. The hydraulic binder composition according to any one of claims 1 to 3, wherein the aluminate cement is selected from the group comprising calcium aluminate cement (CAC), calcium sulfoaluminate cement (CSA), Belite-Ye'elimite-Ferritecement (BYF), and mixtures thereof, preferably from the group comprising them.

5. A hydraulic binder composition according to any one of claims 1 to 4, comprising a sulfate source between 8% by mass and 12% by mass, preferably between 9% by mass and 11% by mass.

6. where the sulfate source is selected from the group consisting of calcium sulfate (CaSO ４ ), sodium sulfate (Na ２ SO ４ ), potassium sulfate (K ２ SO ４ ), lithium sulfate (Li ２ SO ４ ), and mixtures thereof, preferably consisting of the group consisting of, the hydraulic binder composition according to any one of claims 1 to 5.

7. A hydraulic binder composition according to any one of claims 1 to 6, comprising blast furnace slag fine powder in an amount between 50% by mass and 80% by mass, preferably between 60% by mass and 75% by mass.

8. Component d) is between 25 μm and 32 μm. ９０ Preferably between 27 μm and 30 μm. ９０ A hydraulic binder composition according to any one of claims 1 to 7, further comprising the above.

9. Component d) is between 8 μm and 10 μm. ５０ A hydraulic binder composition according to any one of claims 1 to 8, comprising the above.

10. Component d) is between 21 μm and 25 μm. ８５ A hydraulic binder composition according to any one of claims 1 to 9, comprising the above.

11. A dry industrial mortar composition comprising at least one aggregate and the hydraulic binder composition according to any one of claims 1 to 10, mortar in particular for application to floors, in particular screed and self-leveling underlayment (SLU).

12. A wet industrial mortar formulation comprising at least one aggregate, the hydraulic binder composition according to any one of claims 1 to 10, and water, particularly mortar for floor coverings, particularly self-leveling underlayment (SLU).

13. A hardened industrial mortar product obtained from the wet industrial mortar formulation described in claim 12.

14. A method for preparing a wet industrial mortar compound according to claim 12, comprising the step of mixing water, at least one aggregate, and a hydraulic binder composition according to any one of claims 1 to 10, wherein the hydraulic binder composition is prepared in situ before or during the mixing step from different components of the hydraulic binder composition and / or in the form of a premix.

15. The method according to claim 14, wherein the ratio of water to binder composition is between 0.1 and 1.2, preferably between 0.15 and 0.45, and more preferably between 0.2 and 0.4.

Images