Energy-saving and environmentally friendly lightweight precast concrete magnesium wall honeycomb panels

Abstract

This invention relates to a material for an energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel. It primarily uses lightly calcined magnesite powder obtained from calcined magnesite or ash powder (mainly MgO) obtained from low-temperature calcined dolomite as a binder, and water-soluble magnesium salts such as magnesium chloride hexahydrate (MgCl2·6H2O) as a modifier. Water is then added to form lightly calcined magnesium powder and magnesium chloride hexahydrate, which together form magnesium oxychloride cement. Furthermore, a composite admixture technology is used to transform the air-hardening magnesium cement into water-resistant magnesium cement, overcoming the water-intolerant characteristic of magnesium cement. During production, appropriate amounts of polystyrene foam particles are mixed with magnesium oxychloride cement and additives to form a slurry. The slurry is then poured into a frame mold, leveled, pressed, and shaped into blocks. After drying and demolding, the resulting energy-saving, environmentally friendly, lightweight honeycomb precast concrete magnesium wall panel is formed. This invention is a new composite building material that overcomes the shortcomings of magnesium cement in terms of water resistance. It leverages the characteristics of magnesium oxychloride cement, giving the wall panels made from this material advantages such as high strength, high wear resistance, high temperature resistance, low temperature resistance, high fire resistance, resistance to salt corrosion, weather resistance, lightweight and low density, rapid setting, impermeability, earthquake resistance, and ease of processing. It is truly a new technological material for industry.

Description

[Technical Field]

[0001] This invention relates to an energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel. The main technology involves using ash powder (mainly composed of MgO) composite admixtures to transform air-hardening magnesium cement into water-resistant magnesium cement, overcoming the water-intolerant properties of magnesium cement. The magnesium cement is then used to make energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panels, thus creating a new technological material for the construction industry. [Previous Technology]

[0002] Magnesium cement is a special type of cement, invented by the Frenchman Sorel in 1867. It is made by using lightly calcined magnesite powder (from calcined magnesite ore) or ash powder (mainly composed of MgO) from low-temperature calcined dolomite as a binder, and then adding water and water to form magnesium oxychloride cement, which consists of lightly calcined magnesia powder and magnesium chloride hexahydrate.

[0003] Magnesium cement can harden relatively quickly at room temperature and pressure, forming artificial stone that is brittle yet very hard. Therefore, utilizing the hardening and cementing properties of magnesium cement, it can be processed into various building and decorative materials, showing broad application prospects. In practical applications, magnesium oxide and magnesium chloride solutions harden rapidly after mixing and curing, thus requiring no moisture curing. It exhibits excellent flexural and compressive strength, high hardness, and good wear resistance. However, magnesium cement has poor water resistance, which poses a significant obstacle to its industrial use.

[0004] - Traditional reinforced concrete weighs 2500 kg per cubic meter (1 m x 1 m x 1 m). In contrast, a precast magnesium concrete wall panel of the same volume weighs only 400 kg, which is about 1 / 6 of the weight of traditional reinforced concrete. Furthermore, considering a 1 m x 0.5 m x 0.09 m thick precast magnesium concrete wall panel, each precast magnesium concrete wall panel weighs approximately 20 kg, making it the lightest wall panel currently available.

[0005] The inventor team previously had a patent No. I821690, which is a production method and equipment for energy-saving and environmentally friendly lightweight honeycomb precast concrete wall panels. Through a cyclical and continuous processing flow, the quality of energy-saving and environmentally friendly lightweight honeycomb precast concrete wall panels (IHPC) is consistent.

[0006] The honeycomb precast concrete wall panels made by the above-mentioned patented technology are quite lightweight, wind-resistant, airtight, pressure-resistant, heat-insulating, energy-saving, and fireproof, waterproof, earthquake-resistant and soundproof. However, in places with extremely cold, high temperature or harsh climate, their weather resistance is not good. Therefore, the inventors further developed the honeycomb precast concrete magnesium board material and developed an energy-saving and environmentally friendly lightweight precast concrete magnesium wall honeycomb panel. It has high wear resistance, high strength, resistance to salt brine corrosion, resistance to high and low temperatures and good impermeability, making it an excellent composite board material for industry. [Summary of the Invention]

[0007] This invention relates to a material for an energy-saving, environmentally friendly, lightweight precast concrete magnesium honeycomb wall panel. The wall panel made from this material has the advantages of high strength, high wear resistance, high temperature resistance, low temperature resistance, high fire resistance, salt corrosion resistance, weather resistance, lightweight and low density, rapid setting, impermeability, seismic resistance, and easy processing. Using this material to make an energy-saving, environmentally friendly, lightweight honeycomb precast concrete magnesium wall panel helps to strengthen building materials and extend the service life of buildings. It can also resist extreme cold, high temperature and salt corrosion, and has excellent weather resistance.

[0007] The main component is MgO, which is obtained by calcining magnesite or by ash powder (mainly composed of MgO) obtained by low-temperature calcining dolomite. Water-soluble magnesium salts such as magnesium chloride hexahydrate (MgCl2·6H2O) are used as binders. Water is added to form MgO cement. The resulting MgO cement is made from calcined magnesia powder and magnesium chloride hexahydrate. The composite admixture technology is then used to transform the air-hardening magnesium cement into water-resistant magnesium cement, overcoming the water-intolerant property of magnesium cement.

[0009] During production, appropriate EPS particles are added and mixed with magnesium oxychloride cement to form a slurry. The slurry is then poured into a frame mold to level, press, and shape it into a block. After drying and demolding, it becomes an energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb board.

[0010] This invention is a new composite building material that overcomes the disadvantage of magnesium cement being water-resistant and can give full play to the characteristics of magnesium oxychloride cement. The wall panels made of this material have the advantages of high strength, high wear resistance, high temperature resistance, low temperature resistance, high fire resistance, salt corrosion resistance, weather resistance, lightweight and low density, rapid setting, impermeability, seismic resistance and easy processing. This invention uses a frame mold to shape the slurry to achieve consistent shape and quality of energy-saving and environmentally friendly lightweight precast concrete magnesium honeycomb wall panels. Moreover, the equipment has low cost and small size, and can shorten the processing time, which has excellent production efficiency. [Simplified Explanation of the Diagram]

[0011] Figure 1 is a diagram illustrating the material formula of the energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel of the present invention.

[0011] Figure 2 is a formula ratio diagram of the magnesium oxychloride cement material of the present invention.

[0011] Figure 3 is an illustration of the steps for producing the energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel of the present invention.

Implementation Method

[0012] First, the present invention relates to a material for an energy-saving and environmentally friendly lightweight precast concrete magnesium honeycomb wall panel. The wall panel made from this material has the advantages of high strength, high wear resistance, high temperature resistance, low temperature resistance, high fire resistance, salt corrosion resistance, weather resistance, lightweight and low density, rapid setting, impermeability and easy processing. Using this material to make an energy-saving and environmentally friendly lightweight honeycomb precast concrete magnesium wall panel helps to strengthen building materials and extend the service life of buildings. It can also resist extreme cold, high temperature and salt corrosion, and has excellent weather resistance.

[0013] Next, please refer to Figure 1, which is a material formula diagram of the energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel of the present invention. It mainly uses lightly calcined powder obtained from calcined magnesite or ash powder obtained from low-temperature calcined dolomite (main component is MgO) as a binder, and then uses water-soluble magnesium salts such as magnesium chloride hexahydrate (MgCl2·6H2O) as a modifier. Water is then added to form lightly calcined magnesium powder and magnesium chloride hexahydrate to form magnesium oxychloride cement. Then, composite admixture technology is used to transform air-hardening magnesium cement into water-resistant magnesium cement, overcoming the characteristic of magnesium cement not being water-resistant.

[0014] Please refer to Figure 2 for the formula ratio diagram of the magnesium oxychloride cement material of the present invention. The weight and volume ratio of each cubic meter of magnesium oxychloride cement material (1 meter x 1 meter x 1 meter) is 400 kg as follows: polystyrene foam particles: 4~20 kg, accounting for 85%; magnesium oxide: 100~180 kg, accounting for 6%; calcium carbonate (fly ash, mineral powder): 130~200 kg, accounting for 8%; modifier: 15~25 kg, accounting for 0.5%; water: 10~30 kg, accounting for 0.5%; glass fiber mesh: 0.2~1 kg.

[0015] During production, please refer to Figure 3, which is a step-by-step diagram illustrating the production of the energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel of the present invention. a) Add appropriate EPS particles and magnesium oxychloride cement to mix into a slurry; b) Pour the slurry into a frame mold, level it, press it, and shape it into a block; c) After drying, demold to obtain the energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel. The precast concrete magnesium wall honeycomb panel of the present invention, calculated based on a thickness of 1 meter x 0.5 meters x 0.09 meters, weighs approximately 20 kilograms per panel, making it the lightest product among all wall panels currently available.

[0016] The energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel developed in this case has 16 characteristics, as described below:

[0016] (1) Air hardening: Common cementitious materials, represented by general-purpose cement, are all hydraulic, that is, they can harden in water. However, water-resistant magnesium cement is completely different from conventional cement. It is air-hardening and does not harden in water. This is a more prominent feature of water-resistant magnesium cement compared with conventional cement.

[0016] (2) High strength: Water-resistant magnesium cement can easily reach 62.5 MPa. The compressive strength of general light-burned magnesium powder cementitious materials can reach more than 62.5 MPa, and most can reach more than 90 MPa. Under the condition that the quality of light-burned magnesium powder can be guaranteed, the magnesium cement ratio is reasonable, and the process is scientific, it can also reach about 140 MPa. The test shows that when the mass ratio of light-burned magnesium powder to inorganic aggregate is 1:1, its compressive strength can reach 34 MPa and flexural strength 9 MPa in one day. The compressive strength reaches 142 MPa and the flexural strength reaches 26 MPa in 28 days.

[0016] (3) High wear resistance: The wear resistance of water-resistant magnesium cement is three times that of ordinary Portland cement. In the experiment, a floor tile was made using water-resistant magnesium cement and ordinary 32.5 grade ordinary Portland cement respectively. After being cured together for 28 days, the wear resistance test was carried out. The wear resistance length of the ordinary Portland cement floor tile was 34.7 mm, while the wear resistance length of the floor tile made of lightly calcined powder was only 12.1 mm, which is equivalent to 1 / 3 of that of the cement floor tile.

[0016] (4) High temperature and low temperature resistance: Among various inorganic cementitious materials, only water-resistant magnesium cement has the characteristics of both high temperature resistance and low temperature resistance.

[0016] (5) The main component of light-burned powder, MgO, has a refractoriness of 2800℃, ranking first among all commonly used refractory magnesium oxides. Water-resistant magnesium cement not only has excellent high-temperature resistance but also excellent low-temperature resistance. This is because most water-resistant magnesium cements use magnesium chloride as a modifier, and magnesium chloride is an antifreeze chloride salt. Therefore, water-resistant magnesium cement has natural low-temperature resistance, so water-resistant magnesium cement products can be produced normally at low temperatures without the need for external antifreeze. Under normal circumstances, it can withstand temperatures as low as -30℃.

[0016] (6) Resistance to brine corrosion: Water-resistant magnesium cement uses brine as a binder (mostly magnesium chloride), meaning that water-resistant magnesium cement itself contains brine components, so it is not afraid of brine corrosion, and its strength will increase when exposed to brine. This allows water-resistant magnesium cement to overcome the shortcomings of ordinary cement and concrete products and be used in high-salinity areas.

[0016] (7) Air stability and weather resistance: Since water-resistant magnesium cement is air-hardening, it can only continue to set and harden in the air after final setting, which gives it good air stability. The drier the air, the more stable it is.

[0016] (8) Resistance to dry weather: In dry air, the compressive and flexural strength of water-resistant magnesium cement products increase with age, and continue to increase even at two age stages, showing great stability. Therefore, the strength of water-resistant magnesium cement in dry air continues to increase.

[0016] (9) Weather resistance: Due to its resistance to high and low temperatures, water-resistant magnesium cement is stable in both high-temperature and cold climates and its stability is not affected by climate changes. It has excellent weather resistance.

[0016] (10) Low temperature and low corrosion: The alkalinity of water-resistant magnesium cement is much lower than that of any type of conventional cement. According to the test, the pH value of its slurry filtrate fluctuates between 8 and 9.5, which is very low and close to neutral. Because the alkalinity of water-resistant magnesium cement is extremely low, it is only slightly alkaline and has very little corrosiveness to glass fiber and wood fiber. In industrial applications, GRC products have the advantages of being lightweight, high-strength, fireproof, weather-resistant, corrosion-resistant, and earthquake-resistant, and are suitable for building exterior walls, decorative elements, garden landscapes and other fields. It is reinforced with glass fiber, and the fiber-reinforced products are reinforced with wood fiber waste such as sawdust, shavings, cotton stalks, bagasse, peanut shells, rice husks, corn cobs, etc. Glass fiber and wood fiber are both alkali-sensitive materials and are extremely afraid of alkali corrosion. Under high alkali corrosion, glass fiber and wood fiber will lose strength and lose their reinforcing effect on cementitious materials. Therefore, the water-resistant magnesium cement of this invention, with its slightly alkaline advantage, is compatible with GRC and fiber-reinforced products, and can be further made into the best material for inorganic fiberglass.

[0016] (11) Lightweight and low density: The density of water-resistant magnesium cement products is generally only 70% of that of ordinary silicate products. Its product density is generally 1600~1800 kg / m³, while the density of cement products is generally 2400~2500 kg / m³. Therefore, it has a very obvious low density. According to the formula of Connie honeycomb board, it is only 400 kg / m³.

[0016] (12) Rapid setting: Water-resistant magnesium cement has natural rapid setting properties. Generally, after adding a modifier, it can reach the demolding strength in 4~8 hours. The initial setting time of water-resistant magnesium cement is 35~45 minutes, and the final setting time is 50~60 minutes, which is equivalent to rapid-hardening cement. The rapid setting of rapid-hardening cement is formed by the addition of external accelerators, and the production process is complicated, while the rapid setting property of water-resistant magnesium cement is formed naturally by the material itself.

[0016] (13) Good impermeability: After water-resistant magnesium cement sets and hardens, it forms a very high density and has far fewer capillary pores than conventional cement. Therefore, water-resistant magnesium cement has good impermeability after hardening, with a very low permeability coefficient. Even without the addition of impermeable agents, its hardened body can achieve an impermeability grade of S25 or higher.

[0016] (14) High gloss of products: Using a mold with the same gloss, one product was made with water-resistant magnesium cement and one with conventional cement material. The gloss of the two products was then compared. The gloss of the water-resistant magnesium cement product was obviously more ideal than that of the cement product.

[0016] (15) Safe to use, non-toxic and odorless: Water-resistant magnesium cement does not contain any substances harmful to humans, and the products are non-toxic, odorless and non-volatile during the production process.

[0016] (16) Good processability: Water-resistant magnesium cement products have good processability. They can be sawed, planed, nailed, drilled, carved, and pasted, making them very suitable for factory production and on-site processing and installation. They are very convenient to use.

[0017] In summary, this invention is a new composite building material that overcomes the disadvantage of magnesium cement being water-resistant and can leverage the characteristics of magnesium oxychloride cement. This allows the magnesium wall panels made from this material to possess advantages such as high strength, high wear resistance, high temperature resistance, low temperature resistance, high fire resistance, resistance to salt corrosion, weather resistance, lightweight and low density, rapid setting, impermeability, seismic resistance, and ease of processing. This invention utilizes a frame-shaped mold to shape the slurry, achieving consistent shape and quality of energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panels. Furthermore, the equipment has low cost and small size, and can shorten processing time, resulting in excellent production efficiency. Since this invention meets the requirements for an invention patent, a patent application is hereby filed in accordance with the law.

Claims

1. A material for an energy-saving and environmentally friendly lightweight precast concrete magnesium wall honeycomb panel, which mainly uses lightly calcined powder obtained from calcined magnesite ore or ash powder obtained from low-temperature calcined dolomite as a binder, and magnesium chloride hexahydrate as a modifier, and then adds water to form magnesium oxychloride cement composed of lightly calcined magnesium powder and magnesium chloride hexahydrate. The magnesium oxychloride cement has a weight and volume composition of 400 kg per cubic meter (1m x 1m x 1m): polystyrene foam particles: 4~20 kg, accounting for 85%; magnesium oxide: 100~180 kg, accounting for 6%; calcium carbonate: 130~200 kg, accounting for 8%; modifier: 15~25 kg, accounting for 0.5%. Water: 10~30kg, accounting for 0.5%; Fiberglass mesh: 0.2~1kg; During production, add polystyrene foam particles and magnesium oxychloride cement to mix into a slurry, then pour the slurry into a frame mold, level it, press and shape it into a block, and after drying and demolding, it becomes an energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel.

2. The material of the energy-saving, environmentally friendly, lightweight precast concrete magnesium wall honeycomb panel as described in claim 1, wherein, This energy-saving, environmentally friendly, and lightweight precast concrete magnesium wall honeycomb panel weighs approximately 20 kilograms when measured as 1 meter x 0.5 meters x 0.09 meters thick.

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