CONSTRUCTION PANEL WITH HIGH RESISTANCE TO FIRE AND A METHOD FOR PRODUCING A CONSTRUCTION PANEL WITH HIGH RESISTANCE TO FIRE

Abstract

The invention relates to a construction panel with high resistance to fire and to a method for producing a construction panel with high resistance to fire.

Claims

1. Construction panel with high resistance to fire, comprising: xonotlite; expanded perlite; and, fibers.

2. Construction panel according to claim 1 which comprises the xonotlite, the expanded perlite, and the fibers in a proportion of at least 33% by mass.

3. Construction panel according to claim 1, which comprises the fibers in the form of at least one of the following fibers: glass fibers or cellulose fibers.

4. Construction panel according to claim 3, which comprises the glass fibers in the form of AES fibers.

5. Construction panel according to claim 1, which comprises the xonotlite in a proportion in the range of 20 to 50% by mass.

6. Construction panel according to claim 1, which comprises the expanded perlite in a proportion in the range of 8 to 20% by mass.

7. Construction panel according to claim 1, which comprises the expanded perlite amounting to at least 50% by mass, based on the total mass of the expanded perlite, in a grain size of at most 1.5 mm.

8. Construction panel according to claim 1, which comprises the fibers in a proportion in the range of 1.5 to 10% by mass.

9. Construction panel according to claim 3, which comprises the cellulose fibers in a proportion in the range of 1 to 6% by mass.

10. Construction panel according to claim 3, which comprises the glass fibers in a proportion in the range of 0.5 to 5% by mass.

11. Construction panel according to claim 1, further comprising anhydrite.

12. Construction panel according to claim 1, which comprises calcium carbonate.

13. Method of producing a construction panel with high resistance to fire, comprising the following steps: providing a batch comprising: a component comprising calcium oxide; a component comprising silicon dioxide; expanded perlite; fibers; and, water; forming the batch; and applying pressure and temperature to the formed batch such that the component comprising calcium oxide, the component comprising silicon dioxide, and the water form xonotlite.

14. Method according to claim 13, in which the batch comprises at least 50% by mass of the expanded perlite, based on the total mass of the expanded perlite, in a grain size of at most 1.5 mm.

15. Method according to claim 13, in which the batch comprises the expanded perlite in a proportion in the range of 5 to 20% by mass.

Description

EMBODIMENT

[0143] According to one embodiment of the inventive method, a batch was first made available which comprised the components in the proportions of mass according to Table 1 below, each based on the total mass of the batch:

TABLE-US-00001 TABLE 1 Proportion of mass Component [% by mass] Component comprising calcium oxide 36.8 Component comprising silicon dioxide 23.6 Expanded perlite 8.3 Cellulose fibers 1.3 AES glass fibers 0.6 Anhydride 1.3 Thickener 0.2 Foaming agent 0.1 Water 27.8

[0144] The component comprising calcium oxide was in the form of calcium hydroxide.

[0145] The component comprising silicon dioxide was in the form of quartz powder. The quartz powder was 95% by mass, based on the total mass of the quartz powder, with a grain size of less than 50 μm. The quartz powder had a chemical composition with 99% by mass SiO.sub.2, based on the total mass of the quartz powder.

[0146] The expanded perlite was 100% by mass, based on the total mass of the expanded perlite, with a grain size of less than 1.5 mm, and 98% by mass with a grain size of less than 1.0 mm. Furthermore, the expanded perlite was 95% by mass, again based on the total mass of the expanded perlite, and had a grain size between 0.03 and 1.0 mm.

[0147] The cellulose fibers were in the form of Kraft cellulose fibers with a mean fiber diameter of approximately 20 μm and a mean fiber length of approximately 1.9 mm.

[0148] The AES glass fibers had a chemical composition, based on the total mass of the AES glass fibers, of 75% by mass SiO.sub.2 and 22% by mass CaO+MgO. The mean fiber diameter was about 8 μm.

[0149] The foaming agent was in the form of a surfactant (Sika® foaming agent SB 2) and the thickener was in the form of a modified methyl hydroxyethyl cellulose.

[0150] The total proportion of calcium hydroxide and quartz powder had a chemical composition in which the mass ratio of CaO to SiO.sub.2, based on the total mass of calcium hydroxide and quartz powder, was 1.103.

[0151] The batch was mixed in a mixer and then pressed in a commercial hydraulic press with a punch for the production of fire protection panels at a pressure of 0.25 MPa to form a square panel with a side length of 1,250 mm and a thickness of 30 mm.

[0152] The pressed panel was then placed in an industrial autoclave for 12 hours at a pressure of 18 bar at saturated steam pressure and the temperature resulting therefrom (about 207° C.).

[0153] Finally, the correspondingly autoclaved panel was removed from the autoclave and dried in a drying cabinet to a residual moisture content of about 10% by mass.

[0154] The construction panel obtained thereafter was in the form of an inventive construction panel with high resistance to fire.

[0155] This construction panel comprised the following components in the proportions by mass according to Table 2 below, each based on the total mass of the construction panel:

TABLE-US-00002 TABLE 2 Proportion of mass Component [% by mass] Xonotlite 25.6 Expanded perlite 12.0 Cellulose fibers 1.8 AES glass fibers 0.9 Anhydride 0.8 Calcium carbonate 1.2 Tobermorite 24.8 Calcium silicate gel phases 21.5 Quartz 1.9 Scawtite 9.5

[0156] The mineralogical composition of the construction panel was determined by means of X-ray diffraction analysis using the Rietveld method.

[0157] During the microscopic examination of the construction panel, it was found that xonotlite had formed in the open pore volume of the expanded perlite, thereby largely closing the open pores of the expanded perlite.

[0158] The chemical composition of the construction panel was determined by means of X-ray fluorescence analysis according to DIN EN ISO 12676:2013-02. The construction panel then had the substances in the proportions of mass according to Table 3 below, based in each case on the total mass of the construction panel:

TABLE-US-00003 TABLE 3 Proportion of mass Chemical component [% by mass] SiO.sub.2 45.44 Al.sub.2O.sub.3 1.79 Fe.sub.2O.sub.3 0.18 BaO 0.010 MnO 0.029 TiO.sub.2 0.043 V.sub.2O.sub.5 <0.001 CaO 39.60 MgO 0.53 K.sub.2O 0.40 Na.sub.2O 0.59 SO.sub.3 0.09 Other <0.05 Loss on ignition 11.26

[0159] For determining resistance to fire, the fire behavior of the construction panel was carried out in accordance with DIN EN 1363-1:2012-10 in the form of a beam cladding test (box test) without a substructure, wherein the paneling parts were clamped. Then, when the construction panel was temperature-loaded according to the standard temperature curve according to DIN EN 1363-1:2012-10, the onset of panel sagging was determined only after 138 minutes and at a surface temperature of 1011 K. The construction panel thus exhibited excellent fire resistance.