Leveling and noise reducing mortar composition

Abstract

A mortar composition, in particular a leveling mortar composition, including: a) 3-45 wt. % of a hydraulic binder, b) 15-80 wt. % of lightweight aggregates, c) 5-50 wt. % of a polymer.

Claims

1. A mortar composition, comprising: a) 3-45 wt. % of a hydraulic binder, b) 15-80 wt. % of lightweight aggregates comprising at least two different types of particles, the at least two different types of particles including a first type of particles having a particle size in a range of 0.01 mm to 0.5 mm, and a second type of particles having a particle size in a range of 0.6 mm to 2 mm, both the first type of particles and the second type of particles being rubber particles, and c) 5-50 wt. % of a polymer.

2. The mortar composition according to claim 1, wherein the hydraulic binder comprises: 3-18 wt. % of aluminate cement and/or sulphoaluminate cement; wherein all amounts are with respect to a total weight of the mortar composition in dry state.

3. The mortar composition according to claim 1, wherein the hydraulic binder comprises aluminate cement and/or sulphoaluminate cement and latent hydraulic and/or pozzolanic binder materials with a weight ratio of aluminate cement and/or sulphoaluminate cement to the latent hydraulic and/or pozzolanic binder materials in a range from 0.5-3.

4. The mortar composition according to claim 1, wherein a particle density of the lightweight aggregates is in a range from 100-2,000 kg/m.sup.3.

5. The mortar composition according to claim 1, wherein a weight ratio of the first type of particles having a smaller particle size to the second type of particles having a larger particle size is in a range from 1:2-8:1.

6. The mortar composition according to claim 1, wherein the lightweight aggregates or particles have a non-spherical or irregular shape.

7. The mortar composition according to claim 1, wherein the polymer is a water soluble or water redispersible polymer, and/or wherein the polymer has a glass transition temperature in a range of 45-10 C.

8. The mortar composition according to claim 1, comprising: 3-18 wt. % of calcium aluminate cement and/or sulphoaluminate cement; 30-80 wt. % of rubber particles, wherein a weight ratio of the first type of particles having a smaller particle size to the second type of particles having a larger particle is in a range from 2:1-4:1; 1-15 wt. % of porous inorganic particles, with a particle size in a range of 0.1-0.6 mm; 5-20 wt. % of a water soluble or water redispersible polymer; and 0-10 wt. % of one or more additives; wherein all amounts are with respect to a total weight of the mortar composition in dry state.

9. A kit-of-parts comprising (i) the mortar composition according to claim 1, and (ii) an adhesive composition, wherein the adhesive composition comprises: a) 10-50 wt. % of a hydraulic binder, b) 20-60 wt. % of lightweight aggregates, and c) 10-25 wt. % of a polymer; and wherein the mortar composition is chemically different from the adhesive composition.

10. A structure comprising: a substrate; a first layer of the mortar composition according to claim 1, a second layer, comprising a adhesive composition comprising: a) 10-50 wt. % of a hydraulic binder, b) 20-60 wt. % of lightweight aggregates, and c) 10-25 wt. % of a polymer; and a cover element that is fixed to the first layer with the adhesive composition of the second layer.

11. The structure according to claim 10, wherein a thickness of the first layer is larger than a thickness of the second layer, and a ratio of the thickness of the first layer to the thickness of the second layer is in a range from 1.1-10.

12. A method of using the mortar composition according to claim 1, comprising: fixing tiles on a substrate with the mortar composition.

13. A method of using the mortar composition according to claim 1, comprising: performing acoustic damping, noise reduction and/or vibration reduction on a substrate with the mortar composition.

Description

EXEMPLARY EMBODIMENTS

(1) 1. Mortar Compositions

(2) Table 1 shows six mortar compositions M1-M6. The mortar compositions have been prepared by intermixing all of the components in dry state. The mortar composition M1-M6 are present as dry powders.

(3) TABLE-US-00001 TABLE 1 Mortar compositions Component M1 M2 M3 M4 M5 M6 Hydraulic binder [wt. %] Portland cement (CEM I, 42.5N) 8 4 8 Calcium aluminate cement.sup.1) 8 4 8 Calcium sulphoaluminate 9 5 5 cement.sup.2) Fly ash 10 2 Slag Lightweight aggregates [wt. %] Rubber.sup.3) 56 50 34 31 33 Rubber.sup.4) 17 27 43 31 40 71 Expanded glass.sup.5) 3 3 3 Further aggregates [wt. %] Sand 6 Polymer [wt. %] Redispersible copolymer.sup.6) 12.5 12.2 12.4 Redispersible copolymer.sup.7) 10.8 10.0 10.8 Additives [wt. %] Plasticizer.sup.8) 0.05 0.05 0.05 0.04 Layered silicate.sup.9) 0.8 1.0 1.0 Processing additives.sup.10) 1.65 1.75 1.55 1.2 0.06 2.2 .sup.1)Isidac 40, calcium aluminate cement, Cimsa, Turkey .sup.2)Alicem, available from Heidelberg Cement, Germany .sup.3)Prismatic rubber particles, particle size 0-0.4 mm .sup.4)Prismatic rubber particles, particle size 0.6-1.5 mm .sup.5)Poraver, particle size 0.3-0.5 mm, Dennert Poraver GmbH, Germany .sup.6)Soft, flexible vinylacetate-ethylene copolymer (Tg appr. 14 C.) .sup.7)Highly flexible vinylacetate-ethylene-vinylester terpolymer (Tg appr. 14 C.) .sup.8)Sika Viscocrete 225, polycarboxylate ether, Sika Germany .sup.9)Bentonil CV15V, bentonites, Clariant, Gemany .sup.10)Defoamer, rheology modifiers, thixotropic agents

(4) Mortar compositions M1-M6 have been mixed with water (weight ratio of water to total weight of dry mortar composition=0.34-0.64) in order to obtain processable compositions.

(5) Flow table spread values were assessed according to standard EN 12350-5:2009. Directly after preparation values in the range of 250-290 mm were obtained. Thus, the mortar compositions show a flow behavior which makes processing easy.

(6) Internal tests similar to ISO 10140-3:2010 and ISO 717-2 showed that with uncovered mortar compositions, impact noise reductions Lw about up to 20 dB could be achieved.

(7) 2. Adhesive Compositions

(8) Table 2 shows six adhesive compositions C1-C7. The adhesive compositions have been prepared by intermixing all of the components in dry state. The adhesive composition C1-C7 are present as dry powders.

(9) TABLE-US-00002 TABLE 2 Adhesive compositions Component C1 C2 C3 C4 C5 C6 C7 Hydraulic binder [wt. %] Portland cement (CEM I, 42.5N) 20 25 25 30 20 20 35 Portland cement (CEM I, 52.5N) 10 5 Calcium sulphoaluminate cement.sup.1) 5 5 5 5 10 Fly ash 4 5 5 5 4 5 5 Flag 2 2 Lightweight aggregates [wt. %] Rubber.sup.2) 36 41 41 41 Rubber.sup.3) 41 41 41 Expanded glass.sup.4) 5 5 5 5 5 5 5 Polymer [wt. %] Redispersible copolymer.sup.5) 15 16 16 16 15 17 12 Additives [wt. %] Plasticizer.sup.6) 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Fibers.sup.7) 0.5 0.5 0.5 0.5 Accelerator.sup.8) 1.2 1.2 1.2 1.2 1.2 1.2 1.2 Layered silicate 0.5.sup.# 0.3.sup.9) 0.3.sup.9) 0.3.sup.9) 0.5.sup.#) 0.3.sup.9) 0.3.sup.9) Processing additives.sup.10) 0.7 1.4 0.9 0.9 0.7 0.4 0.4 .sup.1)Alicem, available from Heidelberg Cement, Germany .sup.2)Genan 40 Mesh, particle size: 180-425 m, Genan GmbH, Germany .sup.3)Prismatic rubber particles, particle size 0.1-0.4 mm .sup.4)Poraver, particle size 0.1-0.3 mm, Dennert Poraver GmbH, Germany .sup.5)Semi-flexible vinylacetate-ethylene-acrylicacid ester terpolymer .sup.8)Sika Viscocrete 125 P, polycarboxylate ether, Sika Germany .sup.7)Cem-Fil, type 70/30, glass fibers, 3 mm length, 20 m diameter, Owens Corning Composite Materials LLC, USA .sup.8)Calcium formate and Aluminium sulphate .sup.9)Optibent 602, phyllosilicate, Byk-Chemie GmbH, Germany .sup.#)1:1 mixture of Optibent 602 and Optibent Nib, phyllosilicates, Byk-Chemie GmbH, Germany .sup.10)Defoamer, rheology modifiers, thixotropic agents

(10) Adhesive compositions C1-C7 have been mixed with water (weight ratio of water to total weight of dry mortar composition=0.32-0.37) in order to obtain processable compositions.

(11) Tests with the adhesive composition in line with EN 12004-1/2:2017 revealed that properties according to criteria C1E S2 and C2E S2 are achievable.

(12) Internal tests similar to ISO 10140-3:2010 and ISO 717-2 showed that with covering tiles, impact noise reductions Lw of about up to 10 dB can be achieved with the adhesive compositions (without combination with a mortar composition).

(13) 3. Floor Structure with Tiles

(14) A first floor structure was prepared as follows: A substrate in the form of a concrete slab (according to EN 10140-3) was covered with a first layer of mortar composition M1 (as described above in table 1) with a thickness of 10 mm. Subsequently, the first layer was covered with a second layer of adhesive composition C3 (as described above in table 2) with a thickness of 4 mm. On top of the second layer, ceramic tiles with a size of 30 cm60 cm were placed.

(15) For reasons of comparison, a second floor structure was prepared similar to the first floor structure. However, instead of the first layer of mortar composition M1, a conventional bituminous composition was used as the first layer.

(16) Tests according to ISO 10140-3:2010 and ISO 717-2 showed impact noise reductions Lw of 15 dB for the first floor structure whereas impact noise reductions of the second structure was Lw=6 dB.

(17) When comparing the noise reduction data of the adhesives and the floor structures, it is evident that the inventive mortar compositions functionally interact with the adhesive compositions such that high levels of noise reductions can be achieved (it is to be noted that sound levels expressed in decibels are logarithmic and therefore cannot be used for calculation without first being converted back to a linear scale).

(18) Thus, it will be appreciated by those skilled in the art that the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted.