Lightweight Masonry Mix Reducing Bag Weight
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Solution Overview
Problem
Existing pre-mixed mortar, stucco, and masonry mixes are heavy, leading to worker fatigue, increased transportation costs, and environmental impact due to the weight and volume of bags, with existing lightweight cement mixes not addressing the need for a pre-mixed composition including sand.
Innovation Solution
A pre-mixed composition comprising 70-80% sand and 20-30% lightweight cement mix, including Portland or hydraulic cement, fly ash, sodium tall oil, sodium stearate, sodium C14-16 Alpha Olefin, linear alkyl benzene, and silicon dioxide, which reduces the weight of each bag to approximately 65 pounds while maintaining equivalent volume and strength when mixed with water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional pre-mixed mortar, stucco or masonry is used, then strength and structural integrity are achieved, but worker fatigue and transportation costs increase due to heavy weight
Solution Approach 1:
The patent changes the physical-chemical parameters of the cement composition by incorporating specific additives (accelerators, retarders, water reducers) that modify the hydration process and density characteristics, achieving the same strength with reduced weight
Solution Approach 2:
The invention creates a composite cement mixture combining traditional cement with specialized chemical additives and potentially supplementary materials, forming a new composite material that maintains structural properties while reducing density
2Productivity
If larger bags are used to reduce transportation trips, then fewer trips are needed, but worker lifting difficulty and storage space requirements increase
Solution Approach 1:
By changing the density parameter of the cement mixture through additive incorporation, the patent enables larger bag sizes (e.g., 80 pounds) to produce the same volume of mortar as smaller traditional bags, improving transportation efficiency while keeping individual bag weights manageable
3Volume of moving object
If more sand is used to maintain volume equivalence, then volume consistency is achieved, but the overall mixture weight increases
Solution Approach 1:
The patent modifies the density and packing characteristics of the cement-sand-water mixture through chemical additives that affect particle arrangement and water-cement ratio, achieving volume equivalence with reduced overall weight
Data Source
AI summary
An application for a pre-mixed mortar, stucco or masonry composition includes a approximately 75% sand and 25% of a light-weight cement mix comprising a cement (either Portland cement or hydraulic cement), fly ash, sodium tall oil, sodium stearate, sodium C14-16 Alpha Olefin, linear alkyl benzene; and silicon dioxide.