Cement-Free Binder Composition for Low CO2 and Efflorescence Control
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Solution Overview
Problem
Cement-based binder compositions for plasters, mortars, and adhesives have an unfavorable CO2 balance and produce efflorescence, which affects the aesthetic quality of finished surfaces.
Innovation Solution
A cement-free binder composition using blast furnace slag, hydrated lime, and calcium laurate or other water repellents, along with accelerators like CSH seed crystals or calcium formate, to reduce CO2 emissions and prevent efflorescence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cement-based binder compositions are used, then binding performance and setting properties are achieved, but CO2 emissions increase and efflorescence forms on surfaces
Solution Approach 1:
The invention extracts and removes cement clinker from the binder composition entirely, replacing it with a cement-free system based on ground blast furnace slag and hydrated lime. This extraction eliminates the source of efflorescence (cement hydrates) while reducing CO2 emissions associated with cement production, directly addressing both harmful effects identified in the contradiction.
Solution Approach 2:
The invention creates a composite binder system combining ground blast furnace slag (latent hydraulic binder) with hydrated lime and accelerators. This composite material achieves binding performance through synergistic interactions: the slag provides latent hydraulicity while the lime and accelerators enable rapid setting, replacing cement without sacrificing performance and eliminating efflorescence formation.
2Loss of energy
If cement-free binder compositions with ground blast furnace slag and hydrated lime are used, then CO2 emissions are reduced, but setting time increases and binding performance decreases
Solution Approach 1:
The invention incorporates pre-formed accelerators (calcium formate, CSH seed crystals, or calcium hydroxide) into the binder composition before use. These accelerators are prepared in advance to rapidly trigger hydration reactions when water is added, enabling fast setting despite the absence of cement and the use of latent hydraulic binders, thus maintaining productivity while reducing CO2 emissions.
Solution Approach 2:
The invention modifies the chemical and physical parameters of the binder system by using finely ground blast furnace slag with specific surface area characteristics and controlling the ratio of slag to lime. These parameter changes optimize the reactivity and hydration kinetics, enabling rapid setting and binding performance development in the cement-free system while maintaining low CO2 emissions.
3Productivity
If accelerators and hydrophobizing agents are added to cement-free binder compositions, then setting time and water repellency are improved, but composition complexity increases
Solution Approach 1:
The invention employs accelerators that perform multiple functions simultaneously: calcium formate acts as both an accelerator for rapid setting and a water repellent agent; CSH seed crystals serve as both nucleation sites for rapid hydration and structural building blocks. This multi-functionality reduces the need for separate additives, simplifying the overall composition while achieving fast setting and water repellency.
Solution Approach 2:
The binder composition is designed to be self-sufficient through the synergistic interaction of its components. The ground blast furnace slag and hydrated lime combination inherently provides both binding performance and water repellency when combined with the accelerator system, eliminating the need for complex external additives or specialized equipment, and enabling the material to regulate its own setting and protection properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition achieves a more favorable CO2 balance and eliminates efflorescence, enhancing the aesthetic and environmental sustainability of plasters, mortars, and adhesives while maintaining performance.
Implementation Method 1
at least one hydrophobizing agent of the type defined in claim 1... at least one water repellent
Implementation Method 2
latent hydraulic binder, namely granulated blast furnace slag, hydrated lime... accelerators like CSH seed crystals or calcium formate
Data Source
AI summary
The invention relates to a cement-free binder composition comprising a latent hydraulic binder, hydrated lime, and at least one water-repellent agent. The invention further relates to plasters, mortars, and other building materials produced using the binder composition according to the invention. The invention also relates to the use of cement-free binder compositions for preventing efflorescence in plasters, mortars, tile adhesives, and natural stone adhesives.