Use of a Hydraulic Binder Containing Calcium Aluminate for the Production of a Construction Material

Abstract

The invention relates to the use of a hydraulic binder containing calcium aluminate, obtainable by a method in which a) prepared amorphous residual material rich in aluminium oxide and/or aluminium hydroxide is heated after the addition of a b) calcium ion-containing binder component and c) water, for the production of a constructing material.

Claims

1-22. (canceled)

23. A use of a hydraulic binder containing calcium aluminate, obtainable by a method in which a (a) processed amorphous at least alumina-rich or alumina-hydroxide-rich residue after addition of an (b) calcium ion-containing binder component; and (c) water is heated, for the production of a constructing material.

24. The use according to claim 23, wherein the prepared amorphous at least alumina-rich or alumina-hydroxide-rich residue has a degree of crystallization of less than 25%.

25. The use according to claim 23, wherein the processed amorphous at least alumina-rich or alumina-hydroxide-rich residue is formed in the form of a drinking water treatment residue.

26. The use according to claim 23, wherein in that the hydraulic binder containing calcium aluminate has a residual proportion of organic material, the residual proportion preferably being greater than 0.5 wt. %, based on the total mass of the hydraulic binder.

27. The use according to claim 23, wherein the hydraulic binder containing calcium aluminate is substantially anhydrous.

28. The use according to claim 23, wherein the hydraulic binder containing calcium aluminate has a particle size of less than 100 μm.

29. The use according to claim 23, wherein the hydraulic binder containing calcium aluminate is present in the constructing material in a proportion of 0.5 to 65 wt. %, based on the total dry mass.

30. The use according to claim 23, wherein the addition of an ettringite former, preferably at least a calcium-containing or sulfate-containing ettringite former, is provided for the production of the constructing material.

31. The use according to claim 23, wherein the addition of at least Portland cement or hydrated lime or calcium oxide or calcium sulphate is provided for the production of the constructing material.

32. The use according to claim 23, wherein the hydraulic binder containing calcium aluminate is formed in the form of a ternary binder, the ternary binder comprising, in addition to the calcium aluminate-containing component, Portland cement and a sulphate carrier.

33. The use according to claim 23, wherein the ternary binder has a proportion of 20 to 70 wt. % of the calcium aluminate-containing component, 10 to 40 wt. % of sulfate carrier and 0.2 to 20 wt. % of Portland cement, based on the total mass of the ternary binder.

34. The use according to claim 23, wherein the sulphate carrier is formed in the form of alpha calcium sulphate hemihydrate, beta calcium sulphate hemihydrate, anhydrite, calcium sulphate dihydrate or mixtures thereof.

35. The use according to claim 23, wherein the addition of a filler is provided for the production of the construction material, the filler preferably being added in a proportion of 10 to 90 wt. %, based on the total dry mass of the construction material.

36. The use according to claim 23, wherein the filler is formed in the form of limestone powder, quartz sand, marble, chalk, clay, marl, talc or light fillers, such as hollow microspheres of glass, ceramic or plastic, or light fillers, such as expanded glass, expanded mica, expanded perlite, expanded slate, expanded clay, coal fly ash, brick chippings, natural pumice, tuff, lava, slag pumice, boiler sand or a mixture thereof.

37. The use according to claim 23, wherein the addition of additives is provided for the production of the constructing material, the additives preferably being added in a proportion of 0.001 to 10 wt. %, based on the total dry mass of the constructing material.

38. The use according to claim 23, wherein the additives are in the form of liquefiers, retarders, accelerators, actuators, stabilizers, defoamers or sealants.

39. The use according to claim 23, wherein the addition of an epoxy resin and an epoxy hardener is provided for the production of the constructing material, wherein the epoxy resin and the epoxy hardener are preferably added in a total proportion of 10 to 60 wt. % relative to the total dry mass of the constructing material.

40. The use according to claim 23, wherein the addition of plastic dispersion powder is provided for the production of the constructing material, the plastic dispersion powder preferably being added in a proportion of 0.1 to 20 wt. %, based on the total dry mass of the constructing material.

41. The use according to claim 23, wherein the synthetic material dispersion powder is formed on the basis of vinyl or acrylate polymers.

42. The use according to claim 23, wherein the addition of a fibrous material is provided for the production of the constructing material, the fibrous material preferably being added in a proportion of 0.01 to 5 wt. %, based on the total dry mass of the constructing material.

43. The use according to claim 42, wherein the fibrous material has fibres of a length of up to 2 mm.

44. The use according to claim 23, wherein the constructing material is formed in the form of a screed, mortar, filler or tile adhesive.

Description

EXAMPLES OF EMBODIMENTS

[0034] Some exemplary formulations (dry compositions) for constructing materials according to the invention are given below, which can be prepared starting from the use of the hydraulic binder containing calcium aluminate according to the invention (hydraulic binder I) with the addition of the further components listed. The corresponding “ready-to-use” constructing material can then be produced from these proposed dry compositions by adding water. The proportion of water in this case can preferably be 10-150 wt. % relative to the total dry mass of the constructing materials. The designation “hydraulic binder I” is intended to distinguish the hydraulic binder containing calcium aluminate according to the invention in particular from other hydraulic binders, such as Portland cement or alumina cement.

[0035] Tile Adhesive:

[0036] Hydraulic binder I: 30 wt. %

[0037] Portland cement: 15 wt. %

[0038] Sand: 51.6 wt.-%

[0039] Accelerator: 1 wt. %

[0040] Cellulose ether: 0.5 wt. %

[0041] Dispersible powder: 1.8 wt. %

[0042] Fibrous material: 0.1 wt. %

[0043] Putty:

[0044] Hydraulic binder I: 16.5 wt. %

[0045] Portland cement: 5.5 wt. %

[0046] Alumina cement: 5 wt. %

[0047] CaSO4-α-hemihydrate: 9 wt. %

[0048] Sand: 26 wt. %

[0049] Limestone powder: 24 wt. %

[0050] Lightweight aggregates: 10 wt. %

[0051] Dispersible powder: 3 wt. %

[0052] Casein: 0.2 wt. %

[0053] Condenser: 0.5 wt. %

[0054] Stabilizer: 0.02 wt. %

[0055] Retardant: 0.07 wt. %

[0056] Screed:

[0057] Hydraulic binder I: 11.6 wt. %

[0058] Alumina cement: 4 wt. %

[0059] Portland cement: 10.4 wt. %

[0060] CaSO4-α-hemihydrate: 11 wt. %

[0061] Sand: 62 wt. %

[0062] Superplasticizer: 0.05 wt. %

[0063] Setting accelerator: 0.15 wt. %

[0064] Retardant: 0.1 wt. %

[0065] Synthetic Resin Mortar:

[0066] Hydraulic binder I: 29.2 wt. %

[0067] Synthetic resin: 30 wt. %

[0068] Hardener: 3.3 wt. %

[0069] CaSO4-α-hemihydrate: 14.6 wt. %

[0070] Alumina cement: 17.3 wt. %

[0071] Portland cement: 4.8 wt. %

[0072] Setting accelerator: 0.4 wt. %

[0073] Retardant: 0.26 wt. %

[0074] The constructing materials according to the invention listed in the embodiments are not only versatile in use and simple and inexpensive to produce, but also simultaneously make a contribution to sustainable construction, which is provided in particular by the fact that resources are conserved for the production of the constructing materials by using residual or waste materials for production, which would otherwise have to be disposed of in an elaborate and cost-intensive manner.