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WO2024209025A1 - Mortiers auto-nivelants contenant des ciments d'aluminate de calcium - Google Patents

Mortiers auto-nivelants contenant des ciments d'aluminate de calcium Download PDF

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Publication number
WO2024209025A1
WO2024209025A1 PCT/EP2024/059292 EP2024059292W WO2024209025A1 WO 2024209025 A1 WO2024209025 A1 WO 2024209025A1 EP 2024059292 W EP2024059292 W EP 2024059292W WO 2024209025 A1 WO2024209025 A1 WO 2024209025A1
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WO
WIPO (PCT)
Prior art keywords
self
cement
mortar
total weight
levelling
Prior art date
Application number
PCT/EP2024/059292
Other languages
English (en)
Inventor
Olivier Watt
Laurence Martin
Christophe COVENT
Dries DEVLAMINCK
Original Assignee
Holcim Technology Ltd
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Filing date
Publication date
Application filed by Holcim Technology Ltd filed Critical Holcim Technology Ltd
Publication of WO2024209025A1 publication Critical patent/WO2024209025A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/06—Aluminous cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/06—Aluminous cements
    • C04B28/065—Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • C04B2111/62—Self-levelling compositions

Definitions

  • the invention relates to self-levelling mortars, and the processes for preparing said selflevelling mortars. These mortars are useful in particular as underlayments.
  • Self-levelling mortars are characterized by higher flow characteristics and, in contrast to traditional concrete, do not require the addition of excessive amounts of water for placement.
  • Self-levelling mortars are typically used to create a flat and smooth surface, usually with a compressive strength similar to or higher than that of traditional concrete prior to installing interior floor coverings.
  • the use of self-levelling mortars increased as the degree of flatness and smoothness required for floor covering products has increased, with vinyl goods becoming thinner and floor tiles becoming larger, for example.
  • compositions usually mortars, from traditional compositions, which are typically stiffer and require more labour to place, requiring for example additional equipment and work.
  • Self-levelling mortars are mainly used as underlayments or toppings.
  • An underlayment is installed over an existing subfloor to smooth it out and correct any surface irregularities prior to the installation of all types of floor coverings, including sheet vinyl, vinyl composition tile (VCT), wood, ceramic tile and carpet.
  • VCT vinyl composition tile
  • a topping performs a similar function but acts as the actual finished floor without the need for a floor covering.
  • Some typical applications for concrete toppings include warehouse floors, light industrial applications, retail stores and institutional facilities.
  • the present invention thus aims to provide self-levelling mortars containing calcium aluminate cements (CAC) with adapted setting kinetics allowing to limit surface defects, especially when several layers of self-levelling mortars are spread at least in part on each other.
  • CAC calcium aluminate cements
  • CSA cement calcium sulfoaluminate cement
  • the invention concerns the use of CSA to lower the setting kinetic of an amorphous CAC based self-levelling mortar.
  • the invention concerns a premixed binder for self-levelling mortar comprising:
  • a cement C preferably comprising Portland clinker in an amount of at least 30% by weight, preferentially 50% by weight, relative to the total weight of the cement C,
  • the cement comprises mineral components selected from the group consisting of calcium carbonate, silica, ground glass, solid or hollow glass beads, glass granules, expanded glass powders, silica aerogels, silica fume, slags, ground sedimentary siliceous sands, fly ash, pozzolanic materials, ground construction demolition waste or mixtures thereof, and/or o the amorphous phase content of the amorphous CAC is of at least 60% by weight, relative to the total weight of CAC, and/or o the amorphous calcium aluminate cement I calcium sulfoaluminate cement weight ratio ranges from 2:1 to 1 :3, preferably 1 :1 to 1 :3, even more preferably from 1 :1 to 1 :2, and/or o the admixture comprises a plasticizer and/or superplasticizer and/or viscositymodifying agent, and wherein:
  • the plasticizer and/or superplasticizer (expressed in dry extract) is present in a quantity of between 0.01 % and 3 %, preferably between 0.1 % and 2.5 %, with respect to the total weight of the premixed binder, and
  • the viscosity-modifying agent content ranges from 0.005 to 2.0 wt.-%, preferably from 0.01 to 1.0 wt.-%, relative to the total weight of premixed binder, and/or o it comprises up to 15% by weight of additives selected from the group consisting of a resin, water reducer, an accelerator, a retarder, a superabsorbent polymer, a pigment, a defoamer and mixtures thereof, relative to the total weight of the self-levelling premixed binder, and/or o the anhydrite/amorphous CAC weight ratio ranges from 1 :2 to 2:1 , preferably from 1.5: 1 to 1 : 1.5. typically, it is of 1 : 1.
  • the invention concerns a self-levelling mortar comprising the selflevelling premixed binder of the invention, further comprising sand, and typically water.
  • the sand content ranges from 30 wt.-% to 50 wt.-% of sand, preferably from 35 wt.-% to 45 wt.-%, relative to the total weight of the self-levelling premixed binder.
  • the invention concerns the use of the self-levelling mortar of the invention as underlayment or as top layer.
  • the invention concerns a method of levelling a floor, said method comprising: a) providing the self-levelling mortar of the invention, b) casting or pouring the self-levelling mortar of step a) on the floor and spreading it, c) letting the self-levelling mortar of step c) set.
  • step c) of letting the self-levelling mortar set comprises a step c1) of laying a cover layer onto the spread self-levelling mortar.
  • the cover layer is a vinyl sheet, a vinyl composition tile, wood, a ceramic tile or a carpet.
  • the CAC-based self-levelling mortar of the invention provides the following advantages:
  • the self-levelling mortar is excellent for smoothing and flattening surfaces, in particular interior surfaces
  • the self-levelling mortar has improved adhesion to floor coverings such as tiles, carpets, paint, ...
  • the final floor has an excellent visual aspect, be it covered with a cover layer or not,
  • Self-Levelling compositions of the invention are mortars that self-level under the effect of gravity only.
  • Self-levelling mortar are highly liquid compositions to be poured onto a surface, so as to smooth or flatten surfaces, in particular before installing floor coverings. Typically, after setting has occurred, that the final surface is (almost) perfectly horizontal.
  • a premixed binder refers to a dry composition comprising at least cement and admixture, said composition being suitable to be mixed with water and sand for preparing a mortar.
  • Mortar a mortar refers to a composition comprising premixed binder, water and sand, which in the presence of water forms a paste which sets and hardens by means of hydration reactions and processes and which, after hardening, retains its strength and stability even under water.
  • the terms “mortar” and “mortar composition” will have the same meaning in the present disclosure.
  • Total weight of a composition is understood as the total weight of the composition in the dry state, i.e. the total weight of the dry matter of the composition, unless otherwise stated.
  • the cement comprises or preferably consists of Portland clinker and a source of calcium sulfate.
  • the cement is preferably as defined in the standard NF-EN-197-1 of April 2012, or in the standard NF EN 197-5 published in May 2021.
  • the cements defined in these standards are grouped in 6 different families: CEM I, CEM II, CEM III, CEM IV, CEM V and CEM VI.
  • the cement can also be a CEM I, CEM II, CEM III, CEM IV, CEM V or a CEM VI to which mineral components are further added in a second preparation step.
  • the cement may be any mineral binder that comprises Portland clinker optionally mixed with one or several mineral components as defined below.
  • the calcium sulphate content ranges from 0% to 5% by weight of the cement.
  • the cement is essentially free of a calcium aluminate cement and calcium sulfoaluminate cement.
  • Calcium sulphate used according to the present invention includes gypsum (calcium sulphate dihydrate, CaSO4.2H2O), hemi-hydrate (CaSC>4.1/2H2O), anhydrite (anhydrous calcium sulphate, CaSOt) or a mixture thereof. Calcium sulphate produced as a by-product of certain industrial processes may also be used.
  • the mineral component may designate slag (for example, as defined in the European NF EN 197-1 Standard of April 2012, paragraph 5.2.2), pozzolanic materials (for example as defined in the European NF EN 197-1 Standard of April 2012, paragraph 5.2.3), fly ash (for example, as described in the European NF EN 197-1 Standard of April 2012, paragraph 5.2.4), calcined schists (for example, as described in the European NF EN 197-1 Standard of April 2012, paragraph 5.2.5), material containing calcium carbonate, for example limestone (for example, as defined in the European NF EN 197-1 Standard paragraph 5.2.6), limestone components (for example, as defined in the "Concrete” NF P 18-508 Standard), silica fume (for example, as defined in the European NF EN 197-1 Standard of April 2012, paragraph 5.2.7), siliceous components (for example, as defined in the "Concrete” NF P 18-509 Standard), metakaolin or mixtures thereof.
  • the mineral component may also be ground construction demolition waste
  • siliceous components are ground glass, solid or hollow glass beads, glass granules, expanded glass powder.
  • Amorphous calcium aluminate cement (amorphous CAC): amorphous calcium aluminate cement comprises amorphous hydraulic phases having a C/A molar ratio ranging from 0.3 to 15, preferably from 0.5 to 12.
  • the amorphous phase content is of at least 60% by weight and therefore the crystallization phase content is lower than or equal to 40% by weight, relative to the total weight of CAC.
  • the amorphous phase content is preferably at least 65 wt.-%, at least 70 wt.-%, at least 75 wt.-%, at least 80 wt.-%, at least 85 wt.-%, at least 90 wt.-%.
  • Calcium aluminate cements may further comprises at least one crystalline phase selected from CA, C12A7, C3A, C11A7CaF2, C2A(1-x)Fx (with x a member of ]0, 1]), or mixtures thereof.
  • Calcium aluminate cements preferably comprise at least C12A7 phase.
  • Amorphous CAC is further characterized by an alumina (AI2O3) content ranging from 3 to 70% by total weight of the CAC, preferentially ranging from 7 to 50% by weight and better ranging from 20 to 30% by weight.
  • the CAC is essentially free of a cement as defined before, of sulfates, and of CSA as defined below.
  • Amorphous CAC based composition as used herein, an amorphous CAC based composition is understood as a composition comprising amorphous CAC, and cement.
  • Calcium sulfoaluminate cement are calcium aluminate cements that further comprise sulfates, generally in the form of C4A3$ (ye’elimite in the cement chemist notation), which forms at least 50 % of the weight of CSA cement.
  • the CSA is essentially free of cement and of CAC as defined before.
  • the invention concerns a premixed binder for self-levelling mortar comprising:
  • the premixed binder of the invention thus comprises three cements of different nature:
  • amorphous calcium aluminate cement also referred to as “amorphous CAC”
  • the cement C as used in the invention may be any type of cement comprising Portland clinker, whatever its chemical composition is, and whatever its alkaline content.
  • one of the advantages of the invention is not having to select a specific type of cement comprising Portland clinker.
  • the cement C used in the invention is selected from the cements readily available on the market.
  • the cement C is a CEM I or CEM II, optionally further mixed with mineral components, and preferably comprising at least 30 wt.-%, preferentially 50 wt.-%, or more of Portland clinker, relative to the total weight of cement C.
  • the cement C may comprise mineral components (or mineral additions) as defined above.
  • Suitable mineral components are preferably selected from calcium carbonates such as limestone, silica, ground glass, solid or hollow glass beads, glass granules, expanded glass powders, silica aerogels, silica fume, slags such as granulated blast furnace slag, ground sedimentary siliceous sands, fly ash, pozzolanic materials, construction waste or mixtures thereof.
  • the mineral components are preferably in the form of particles having a Dv90 of 200 pm or less, and more preferably a Dv97 of 200 pm or less. Particle size can be measured by laser granulometry using for example a Malvern MS2000.
  • Mineral components of different natures calcareous, siliceous, fly ash, silica fume
  • the mineral components include calcareous, siliceous, and silico-calcareous materials. They include natural, artificial, waste and recycled materials.
  • the mineral components may also comprise, for example, wood.
  • the mineral components content of the premixed binder ranges from 0 to 70 wt-%, preferentially from 10 to 50 wt-%, relative to the total weight of the premixed binder.
  • the premixed binder for self-levelling mortar comprises 50 wt.-% or more, preferably 60 wt.-% or more, even more preferably 70 wt.-% or more, of cement C relative to the total weight of the premixed binder.
  • the premixed binder for self-levelling mortar preferably comprises up to 85 wt.-% of cement C relative to the total weight of the premixed binder.
  • the premixed binder comprises from 0.25 to 7.5 wt.-%, preferably from 0.3 to 3.0 wt.-%, even more preferably from 0.4 to 2.0 wt.-% of amorphous CAC relative to the total weight of premixed binder.
  • Amorphous CAC usually accelerates setting times of the mortars.
  • the premixed binder comprises from 0.25 to 7.5 wt.-% of anhydrite, preferably from 0.3 to 3.0 wt.-%, even more preferably from 0.4 to 2.0 wt.-%, relative to the total weight of the premixed binder.
  • the anhydrite/amorphous CAC weight ratio ranges from 1 :2 to 2:1 , preferably from 1.5: 1 to 1 : 1.5. typically, it is of 1 : 1.
  • Anhydrite is or consists essentially of anhydrous calcium sulphate (CaSOt). It may be obtained by calcination of gypsum, under temperatures sufficiently high for the gypsum to be completely dehydrated.
  • CaSOt calcium sulphate
  • Anhydrite may be natural (rock which must be ground before use) or synthetic (e.g. byproduct during the manufacture of hydrofluoric acid).
  • the premixed binder comprises from 0.5 to 5 wt.-%, preferably from 0.8 to 4.0 wt.-%, even more preferably from 1 .0 to 3.5 wt.-% of CSA relative to the total weight of premixed binder.
  • the premixed binder of the invention has an amorphous CAC/CSA weight ratio ranging from 2:1 to 1 :3, preferably 1 :1 to 1 :3, even more preferably from 1 :1 to 1 :2.
  • the premixed binder may comprise from 0.5 to 5% by weight, compared to the total weight of the premixed binder, of calcium sulfate. This is the content of calcium sulfate added in addition to the calcium sulfate already present in the cement C.
  • the admixture is added, for example, either in the mortar, preferably in a water-soluble sachet, or with a portion of the water, or in the premixed binder composition, or in multiple vectors.
  • the admixture preferably comprises at least one rheology agent.
  • the rheology agent helps to prevent bleeding and segregation. It can also improve robustness of the resulting mortar.
  • the admixture may also comprise water reducing agents (i.e., plasticizers and/or superplasticizers) and viscosity modifying agents (VMAs).
  • water reducing agents i.e., plasticizers and/or superplasticizers
  • VMAs viscosity modifying agents
  • a plasticizer or a superplasticizer is an additive which, by its addition, helps reduce the demand for water and maintain the fluidity/rheology of the paste.
  • plasticizers By way of example of plasticizers, mention may be made of lignosulphonates, hydroxycarboxylic acids, carbohydrates, and other specific organic compounds, for example glycerol, polyvinyl alcohol, sodium alumino-methyl-siliconate, sulfanilic acid and casein as described in the Concrete Admixtures Handbook, Properties Science and Technology, V.S. Ramachandran, Noyes Publications, 1984.
  • Superplasticizers have been generally classified into four groups: sulfonated naphthalene-formaldehyde (SNF) condensates (generally a sodium salt); sulfonated melamine-formaldehyde (SMF) condensates; modified lignosulfonates (MLS); and the others.
  • SNF sulfonated naphthalene-formaldehyde
  • SMF sulfonated melamine-formaldehyde
  • MLS modified lignosulfonates
  • More recent superplasticizers include polycarboxylic compounds such as polycarboxylates, e.g. polyacrylates. Acrylic copolymer-based superplasticizers may also be used, preferably these are polymers comprising a chain with a polycarboxylic function, optionally salified, to which another group (e.g. of the polycarboxylate or polyoxyethylene type) is attached.
  • a superplasticizer is preferably a new generation superplasticizer, e.g. a copolymer containing polyethylene glycol as a grafted chain and carboxylic functions in the main chain like a polycarboxylic ether.
  • Polycarboxylates such as polycarboxylate ether (PCE) are particularly suitable.
  • the superplasticizer is a polycarboxylate, in particular a polycarboxylate ether or ester.
  • the superplasticizers are polycarboxylates that have at least the following three repeating units: an acrylic unit, a methacrylic acid unit, and a unit formed of a long chain of polyethers.
  • These types of dispersing agents or superplasticizers are very effective, especially for improving fluidity. A high dispersion efficiency also helps reduce the quantity of superplasticizers used and has an economic benefit given that the carboxylate-based product is relatively expensive.
  • Sodium polycarboxylate-polysulfonates and sodium polyacrylates may also be used.
  • Phosphonic acid derivatives and polycarboxylates having phosphate groups may also be used.
  • Sodium polycarboxylate-polysulfonates and sodium polyacrylates may also be used.
  • the quantity of plasticizer and/or superplasticizer is very dependent on the nature of the plasticizer and/or superplasticizer and its dilution; however, dosages will be given with 100 % dry extract.
  • the plasticizer and/or superplasticizer (expressed in dry extract) is usually present in a quantity of between 0.01 % and 3 %, preferably between 0.1 % and 2.5 %, with respect to the total weight of the premixed binder.
  • the superplasticizer is usually added in powder form, but an addition in liquid form is also possible. Addition in liquid form generally allows automated dosage of the additives.
  • VMAs prevent bleeding and segregation and improve robustness of the cement slurry and mortars.
  • Viscosity modifying agents are agents able to modify yield stress, viscosity, and thixotropy of the cement slurry.
  • VMAs are also known in the art as viscosity modifying admixtures, viscosity enhancing agents (VEAs), or stabilizing agents (SAs), or yield stress modifying agent.
  • VMAs are usually biobased polymers, and include: cellulose derivatives, for example water-soluble cellulose ethers, such as the sodium carboxy methyl, methyl, ethyl, hydroxyethyl and hydroxypropyl ethers; alginates; and natural gums such as xanthan, carrageenan, wellan, diutan or guar gum; and starch. Combination thereof may also be used (see for instance https://doi.Org/10.1016/j.cemconres.2021.106646).
  • the viscosity modifying agent is an amphiphilic bio-based polymer.
  • the VMA is a polymer derived from cellulose. Even more preferably the VMA is chosen among Methyl Cellulose, methylhydroxyethyl cellulose, hydroxypropylmethyl cellulose and mixture thereof.
  • the VMA comprises or consists of xanthan gum or a polymer derived from xanthan gum, such as diutan gum. Mixtures of polymer derived from cellulose and of xanthan gum or a polymer derived from xanthan gum can also be contemplated.
  • the viscosity-modifying agent content ranges from 0.005 to 2.0 wt.-%, preferably from 0.01 to 1.0 wt.-%, relative to the total weight of premixed binder.
  • the admixture comprises a plasticizer and/or a superplasticizer and/or a VMA. Even more preferably, the admixture comprises a superplasticizer and a VMA.
  • the premixed binder further comprises up to 15 % of further additives by weight relative to the weight of premixed binder.
  • the quantity is expressed in g of active ingredient per 1 L of solution.
  • the additives are selected from the group consisting of: a resin, to improve abrasion resistance or surface adhesion of the mortar to a cover layer such as tiles, a pigment, to provide a decorative effect, an accelerator and/or a retarder, to further modify the setting time of the composition, a defoaming agent, to avoid formation of foams and bubbles, and mixtures thereof.
  • the premixed binder further comprises a resin, and preferably up to 10 wt.-% of resin, such as between 1.5 wt.-% and 5 wt.-%, relative to the total weight of premixed binder.
  • the premixed binder may further comprise an accelerator (or accelerating agent).
  • the accelerator is typically as defined in the standard NF EN 934-2 of September 2012. Suitable accelerators may for example be selected from:
  • alkaline metal or alkaline earth metal salts especially potassium salts, calcium salts and sodium salts wherein the anion may be nitrate, nitrite, chloride, formate, thiocyanate, bromide, or mixtures thereof;
  • alkali metal or alkaline earth metal silicates and aluminates for example sodium silicate, potassium silicate, sodium aluminate, potassium aluminate, or mixtures thereof.
  • the cement for the self-levelling mortar slurry may comprise a CAC accelerator, such as lithium salts.
  • the premixed binder may further comprise an accelerator in an amount ranging from 0.2 to 2.0 % by weight, relative to the total weight of the premixed binder.
  • the additives may also comprise a retarder.
  • Retarders are typically as defined in the standard NF EN 934-2 of September 2012. Suitable retarders may for example be selected from sucrose, alpha hydroxyacids or salts thereof, ethanolamines or salts thereof, and/or catechols and derivatives thereof. Particularly preferred are alpha hydroxyacids and salts thereof, in particular alkali metal salts thereof.
  • the salt may be selected from the group consisting of tartrate, citrate, lactate, malate, benzoate, acetate, and combinations thereof.
  • the retarder is tartaric acid, calcium or sodium tartrate, citric acid, or calcium and sodium citrate.
  • the premixed binder also comprises a defoaming agent (also called defoamer or anti-foaming agent).
  • a defoaming agent also called defoamer or anti-foaming agent.
  • defoaming agent varies. It may notably be based on silicone, fatty alcohols, esters, or polypropylene glycol.
  • the defoaming agent may in particular be selected from the following classes:
  • Oil-based defoaming agents which has an oil as a vehicle. This oil may be mineral or vegetable (except silicone).
  • the defoamer also comprises a wax and/or a hydrophobic silica. Waxes are, for example, ethylene bis stearamide (EBS), paraffin waxes, ester waxes and fatty alcohol-based waxes. Surfactants may also be present; - Powdered defoaming agent. These agents correspond to oil-based agents but on a particulate medium such as silica;
  • oils are generally oils or waxes dispersed in an aqueous base.
  • the oils are white oils or vegetable oils and the waxes are fatty alcohols, fatty acids, esters or the soaps therefrom;
  • Silicone defoaming agents These defoamers have a silicone as the active agent. They may be oil-based or water-based. A hydrophobic silica may be dispersed in the silicone medium. Emulsifiers may be used. Modified silicones such as glycol silicones or fluorosilicones may also be used.
  • the defoaming agent may be a polydimethylsiloxane. Particularly suitable are silicones comprising (RSiOO.5) and (R2SiO) groups. In these formulas, the radicals R, which may be identical or different, are preferably one hydrogen atom or an alkyl group of 1 to 8 carbon atoms, the methyl group being preferred. The number of repeat units is preferably from 30 to 120;
  • - Glycol type defoaming agents comprise polyethylene glycol and polypropylene glycol copolymers. They are available on an oily or aqueous base or emulsions;
  • the quantity of defoaming agent typically ranges from 0.01 wt.-% to 5 wt.-%, preferably from 0.1 wt.-% to 2 wt.-%, calculated with respect to the total weight of premixed binder.
  • the defoaming agent is generally added in powder form, but an addition in liquid form is also possible. Addition in liquid form generally allows automated dosage of the additives.
  • Water is added to the premixed binder as disclosed above in an amount sufficient to provide the desired flowability and self-levelling properties to the resulting mortar.
  • the water content of the mortar ranges from 16 to 26 wt.-%, more preferably from 18 to 24 wt.-%.
  • the water content is equal to 23 wt.-% relative to the total weight of the mortar including water.
  • Sand and water are added to the premixed binder, or sand is added to the cement slurry to prepare a mortar.
  • the sands that are used in the mortar are conventional aggregates in conformity with the standard EN 12620 (sands for concrete). In practice, the Dmax is less than 4 mm, preferentially less than 1 mm, and even more preferentially less than 500 pm.
  • the sands include calcareous, siliceous and silico-calcareous materials.
  • the sand may be of different origins, washed alluvial (rolled, semi-crushed or crushed), sands of marine origin, crushed limestone sands (dry or washed), sands of magmatic origin (porphyry, granite), recycling aggregates from the crushing of concretes or other construction materials.
  • Clay inerting agents are compounds that help reduce or prevent the harmful effects of clays on the properties of hydraulic binders. Clay inerting agents include those described in FR 2 948 118, WO 2006/032785 and WO 2006/032786.
  • the sand content of the self-levelling mortar ranges from 20 to 80 wt.-%, preferentially from 40 to 60 wt.-%, relative to the total weight of the self-levelling mortar.
  • the self-levelling mortar once spread and subjected to the effect of gravity, has no defects visible to the naked eye, namely no apparent bubbles or unevenness.
  • no apparent unevenness means that, once spread and subjected to the effect of gravity, the self-levelling mortar has a substantially even and flat surface.
  • the exposed (superior) surface of the self-levelling mortar is essentially free of visible reliefs or 3-dimensional motifs.
  • the self-levelling mortar typically has a good compressive strength.
  • the mortar has a compressive strength of between 15 to 40 MPa after 28 days.
  • the premixed binder comprises or consist of:
  • cement C comprises Portland clinker in an amount of at least 30% by weight, preferentially 50% by weight, relative to the total weight of the cement C,
  • the premixed binder has an amorphous CAC/CSA weight ratio ranging advantageously from 1 :1 to 1 :4, preferably from 1 :1.5 to 1 :3, and an amorphous CAC/CSA weight ratio ranging from 2:1 to 1 :3, preferably 1 :1 to 1 :3, even more preferably from 1 :1 ,5 to 1 :2.
  • the total of all components within the premixed binder totals 100 wt.-%.
  • the premixed binder can then be: mixed with sand, preferably with a sand content of 30 to 50 wt.-% of the weight of mortar,
  • the dry mortar preferably comprises, in weight compared to the total weight of the dry mortar: from 50 wt.-% to 70 wt.-% of the premixed binder, preferably from 55 wt.-% to 65 wt.-%, from 30 wt.-% to 50 wt.-% of sand, preferably from 35 wt.-% to 45 wt.-%.
  • Any conventional process for preparing a mortar is suitable to prepare the mortar of the invention.
  • cements as disclosed above cement C, CAC, CSA
  • anhydrite and optionally calcium sulfate can be mixed, in the contents disclosed above, to for a premix. All or part of the admixtures can be added to the premix.
  • the invention further concerns the use of the self-levelling mortar of the invention as underlayment or top layer.
  • the floor may have defects and be uneven. It may be a concrete, wooden or tiled floor, and may be covered in places with cut back adhesives. Also, the floor may have a sloping.
  • the mortar is left to set long enough to flatten and allow bubbles to migrate out of the mortar.
  • a gauge rake may be used to move the mortar into place without spreading it too thin.
  • the finishing is preferably done by lightly breaking the surface tension of the setting mortar using a for instance a smoother.
  • the setting time is measured according to the standard NF EN 196-3 published in January 2009.
  • a mini press is used for measuring low resistances.
  • Fig. 1 shows a heat development curve of a reference mortar (dotted line) and of a mortar of the invention (plain line).
  • Y-axis show temperature in °C, while the X-axis shows the time in minutes.
  • Fig. 2 shows a photograph of the reference mortar after setting. Visual defects such as bubble holes are clearly visible.
  • Fig. 3 shows a photograph of an example of inventive mortar after setting.
  • the exposed surface is flat and even, with no visual defects.
  • the cement used is a mix of a CEM I 52.5R HER supplied by CBR and a filler (or mineral addition).
  • the mineral addition is a calcium carbonate filler: Calcitec 2000 filler supplied by CARMEUSE.
  • Amorphous CAC and anhydrite are provided by Leap Fit supplied by IMERYS which is composed of 50 wt.-% amorphous CAC and 50 wt.-% anhydrite.
  • the CSA is Calumex Quick supplied by Caltra.
  • the admixture composition makes use of Melfux 2651 F (a superplasticizer), Starvis 3003 F (a VMA, hereinafter “VMA 1”) supplied by BASF as powders, and Kelco-crete DG-F (a VMA hereinafter “VMA 2”) supplied by CP Kelco as a powder.
  • VMA 1 a superplasticizer
  • VMA 2 Kelco-crete DG-F
  • the accelerator is U2CO3 (calcium aluminate-based accelerator) supplied by RodaChem as a powder with a granulometry of 40 pm or less.
  • the sand is M32 sand supplied by SIBELCO.
  • o Na2COs is supplied as a powder by TATA or SOLVAY, which decreases shrinkage and delays the setting time.
  • o L-Tartaric acid (a retarder) is supplied by RFI (food ingredients).
  • o a defoamer Agitan P804, supplied by MUNZING.
  • the following mortars were prepared: The mortar is prepared by mixing all dry ingredients in a static mixer, and then progressively adding all liquid components. The W/C is within the range described herein. Mixing is done for a duration of 5 minutes.
  • Mortar 1 is a mortar according to the invention, as it comprises cement C, amorphous CAC, CSA and anhydrite.
  • Figure 1 shows that the initial setting time is unchanged when 2 parts by weight (around 1.95 wt.-%) CSA is added. However, the final setting is increased, as the slope of temperature as a function of time is not as steep. This means that the mortar takes more time to harden and structure itself, allowing the bubbles and surface defects to migrate out of the mortar.
  • Figure 2 shows the results obtained with the reference mortar
  • Figure 3 shows the results obtained with mortar 1 , after pouring a second batch of 1 liter after 10 minutes.
  • the mortar of Figure 2 shows bubbles (see left) and unevenness (see centre).
  • the surface of the mortar in Figure 3 shows a smooth, flat and even surface.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention concerne l'utilisation de CSA pour abaisser la cinétique de prise d'un mortier auto-nivelant à base de CAC amorphe. L'invention concerne en outre une suspension de ciment et un mortier auto-nivelant, le liant pré-mélangé comprenant : ∙ un ciment C, comprenant de préférence du clinker Portland en une quantité d'au moins 30 % en poids, de préférence 50 % en poids, par rapport au poids total du ciment C, ∙ de 0,25 à 7,5 % en poids de ciment d'aluminate de calcium amorphe, CAC, par rapport au poids total du liant prémélangé, ∙ de 0,25 à 7,5 % en poids d'anhydrite, par rapport au poids total du liant prémélangé, ∙ de 0,5 à 5 % en poids de ciment de sulfoaluminate de calcium, CSA, par rapport au poids total du liant prémélangé, ∙ une composition d'adjuvant, en une quantité suffisante pour fournir des propriétés auto-nivelantes au mortier. L'invention concerne en outre l'utilisation du mortier auto-nivelant comme sous-couche ou comme couche supérieure.
PCT/EP2024/059292 2023-04-05 2024-04-05 Mortiers auto-nivelants contenant des ciments d'aluminate de calcium WO2024209025A1 (fr)

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EP23305497 2023-04-05
EP23305497.2 2023-04-05

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006032786A2 (fr) 2004-09-21 2006-03-30 Lafarge Compositions d'inertage d'impuretes
WO2006032785A2 (fr) 2004-09-21 2006-03-30 Lafarge Procede d'inertage d'impuretes
FR2948118A1 (fr) 2009-07-17 2011-01-21 Coatex Sas Additif d'inertage des impuretes pour les suspensions aqueuses de sulfate de calcium hemihydrate contenant un polymere peigne et un polymere cationique
WO2013040788A1 (fr) * 2011-09-23 2013-03-28 Rohm And Haas Company Mortier pour basse température pour système de finition d'isolation extérieure
US20190119163A1 (en) * 2016-06-09 2019-04-25 Basf Se Hydration control mixture for mortar and cement compositions
EP4011624A1 (fr) * 2020-12-08 2022-06-15 Imertech Liant hydraulique à faible empreinte carbone et à résistance initiale élevée

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006032786A2 (fr) 2004-09-21 2006-03-30 Lafarge Compositions d'inertage d'impuretes
WO2006032785A2 (fr) 2004-09-21 2006-03-30 Lafarge Procede d'inertage d'impuretes
FR2948118A1 (fr) 2009-07-17 2011-01-21 Coatex Sas Additif d'inertage des impuretes pour les suspensions aqueuses de sulfate de calcium hemihydrate contenant un polymere peigne et un polymere cationique
WO2013040788A1 (fr) * 2011-09-23 2013-03-28 Rohm And Haas Company Mortier pour basse température pour système de finition d'isolation extérieure
US20190119163A1 (en) * 2016-06-09 2019-04-25 Basf Se Hydration control mixture for mortar and cement compositions
EP4011624A1 (fr) * 2020-12-08 2022-06-15 Imertech Liant hydraulique à faible empreinte carbone et à résistance initiale élevée

Non-Patent Citations (4)

* Cited by examiner, † Cited by third party
Title
LE SAOÛT GWENN ET AL: "Hydration of Portland cement with additions of calcium sulfoaluminates", CEMENT AND CONCRETE RESEARCH, vol. 43, 9 November 2012 (2012-11-09), pages 81 - 94, XP028960023, ISSN: 0008-8846, DOI: 10.1016/J.CEMCONRES.2012.10.011 *
NOOR LAMIYA ET AL: "A critical review of the role of ettringite in binders composed of CAC-PC-C$ and CSA-PC-C$", vol. 106, no. 6, 17 February 2023 (2023-02-17), US, pages 3303 - 3328, XP093092634, ISSN: 0002-7820, Retrieved from the Internet <URL:https://onlinelibrary.wiley.com/doi/full-xml/10.1111/jace.19014> [retrieved on 20231018], DOI: 10.1111/jace.19014 *
V.S. RAMACHANDRAN: "Concrete Admixtures Handbook, Properties Science and Technology", 1984, NOYES PUBLICATIONS
ZHANG SHUPENG ET AL: "Effect of calcium sulfate type and dosage on properties of calcium aluminate cement-based self-leveling mortar", CONSTRUCTION AND BUILDING MATERIALS, vol. 167, 12 February 2018 (2018-02-12), Netherlands, pages 253 - 262, XP093092193, ISSN: 0950-0618, DOI: 10.1016/j.conbuildmat.2018.01.146 *

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