Lightweight Fireproof Panels Using Fly Ash Composite
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Solution Overview
Problem
There is a need for fireproof materials with high fire resistance, low density, and environmental sustainability in the construction industry, as existing materials often lack these properties or have high carbon footprints.
Innovation Solution
A dry mixture composition comprising 30-80% type F fly ash, 0-30% reactive silicon source, at least 1.5% solid alkaline agent, 0.5-10% setting accelerant, and 2-15% lightweight aggregate, which sets at ambient temperature and provides excellent fire-resistant and mechanical strength properties when mixed with water, allowing for lightweight fireproof panels and coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional construction materials are used to achieve fire resistance, then fire protection is provided, but the materials have high density and high carbon footprint
Solution Approach 1:
The invention uses a composite material system combining fly ash (30-80 wt%), reactive silicon source (0-30 wt%), lightweight aggregate (2-15 wt%), solid alkaline agent (≥1.5 wt%), and setting accelerant (0.5-10 wt%). This composite achieves fire resistance exceeding 120 minutes while maintaining low density under 900 kg/m3, resolving the contradiction between fire protection and weight.
Solution Approach 2:
The invention changes the chemical and physical parameters of the fireproof material by using fly ash as the main component (30-80 wt%) instead of traditional heavy materials, and by controlling the density parameter to be under 900 kg/m3. This parameter optimization achieves both fire resistance and lightweight properties simultaneously.
2Object-generated harmful factors
If fly ash is used as the main component to reduce density and carbon footprint, then environmental sustainability is improved, but fire resistance may be compromised
Solution Approach 1:
The invention converts fly ash, a waste material from coal combustion, into a beneficial fireproof building material. By using 30-80 wt% fly ash combined with reactive silicon source and lightweight aggregate, the invention achieves fire resistance exceeding 120 minutes while reducing carbon footprint and utilizing waste resources.
Solution Approach 2:
The composite material system combines fly ash with reactive silicon source (0-30 wt%) and other components to achieve both environmental sustainability and fire resistance. The synergistic effect of the composite components ensures that fire protection requirements are met while utilizing waste materials.
3Ease of operation
If ambient temperature setting is used to simplify application process, then ease of operation is improved, but mechanical strength may be insufficient
Solution Approach 1:
The invention changes the setting conditions parameter to ambient temperature curing, eliminating the need for complex heating equipment. The composition includes setting accelerant (0.5-10 wt%) that enables the material to achieve mechanical compressive strength of at least 0.8 MPa within 28 days at ambient temperature, resolving the contradiction between ease of operation and strength development.
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 mechanical compressive strength of at least 0.8 MPa and fire resistance exceeding 120 minutes, with a density under 900 kg/m3, making it suitable for wall and ceiling gunning while being environmentally friendly due to its use of waste materials.
Implementation Method 1
between 30 and 80% by weight of type F fly ash, at least 1.5% by weight of a solid alkaline agent, and at least 0.5 and 10% of a setting accelerant
Implementation Method 2
between 2 and 15% by weight of a lightweight aggregate, where the % by weight is with respect to the total weight of the composition in a dry mixture form, said composition has a density under 900 kg/m3
Data Source
AI summary
The present invention relates to a composition in the form of a mixture comprising F-type fly ash, a reactive silicon source, a setting accelerator and a light aggregate with a density of less than 900 kg/m3 and a mechanical strength of at least 0.08 MPa, and the uses thereof to obtain light and fireproof construction materials.