Dry Mortar Composition for Drainage Paving
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Solution Overview
Problem
Current methods for creating paved areas in bound construction require a mixing machine to prepare a moistened mortar, which is time-consuming and cumbersome.
Innovation Solution
A dry mortar mixture is evenly distributed in dry form on a solid, water-permeable surface, and paving stones or panels are placed on it. A fine spray of water is applied to penetrate through joints and react with the dry mortar mixture, providing a protective strength and allowing for gradual consolidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mixing machine is used to prepare moistened mortar, then the mortar can be applied to the substrate, but the process becomes time-consuming and cumbersome
Solution Approach 1:
The mortar is prepared in advance as a dry mixture with controlled composition (cement, aggregates, fibers, and water-retaining additives) and stored in containers. This preliminary preparation eliminates the need for on-site mixing operations, allowing direct application to the substrate and significantly reducing preparation time and effort.
Solution Approach 2:
The mixing function is extracted from the on-site construction process and transferred to centralized manufacturing facilities. The dry mortar mixture is produced and packaged there, then transported to the construction site where it can be applied directly without requiring mixing equipment or labor.
2Device complexity
If dry mortar mixture is applied without water, then no mixing machine is needed, but the mortar cannot achieve proper consolidation
Solution Approach 1:
The mortar composition is modified by incorporating water-retaining additives (such as superabsorbent polymers or hydrocolloids) that change the water absorption parameters. These additives control the release of bound water to aggregates and ensure proper consolidation without requiring external water application or mixing equipment.
Solution Approach 2:
The dry mortar mixture contains self-regulating water-retaining components that automatically manage their own water distribution. The mixture self-regulates the water-cement ratio during hardening, ensuring proper consolidation and strength development without external intervention or complex mixing systems.
3Reliability
If water is applied to the paved surface, then the mortar can consolidate, but the water may wash out fine particles from the dry mortar mix
Solution Approach 1:
The composition parameters are adjusted by incorporating water-retaining additives that modify the water absorption characteristics. These additives create a controlled water release mechanism that prevents excessive water flow, thereby preventing fine particle washout while ensuring adequate moisture for consolidation.
Solution Approach 2:
The water-retaining additives are distributed locally within the mortar matrix to create zones of controlled water absorption. This local quality variation ensures that water is released where needed for consolidation while preventing uncontrolled water flow that would wash out fine particles from the aggregate mixture.
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
This method eliminates the need for a mixing machine, allows for quick development of a protective strength, and achieves a final strength comparable to conventional bound construction paving surfaces.
Implementation Method 1
the CSA cement to react very quickly with the quicklime and the added water. This creates a protective hardening on the surface of the dry mortar mix
Implementation Method 2
the reaction of the amorphous CSA cement and, if applicable, of the amorphous CA cement mixed with sulfur trioxide with the quicklime as the second binder component and the water
Implementation Method 3
Thanks to the hydrophilic, inert fibers contained in the dry mortar mix, the dry mortar mix below the paving stones or slabs does not collapse, but has an inherently water-permeable structure
Implementation Method 4
The fine spray now penetrates through the joints and gaps between the paving stones or slabs to the underlying layer of dry mortar mix
Data Source
AI summary
Dry mortar mix for the production of drainage mortar containing 20 to 40 wt.% of a binder mixture, 1 to 5 wt.% hydrophilic, inert fibers, and optionally 0 to 40 wt.% further aggregates and rock particles up to a total of 100 wt.%. The binder mixture, based on the dry mortar mix, comprises 1 to 10 wt.% of a first binder component consisting of amorphous CSA cement or amorphous CA cement modified with sulfur trioxide, 0.1 to 5 wt.% quicklime as a second binder component, 5 to 15 wt.% alumina cement as a third binder component, and 1 to 15 wt.% CEM I R cement as a fourth binder component.