MORTAR COMPOSITION AND ITS USE IN CONSTRUCTION

Abstract

Mortar composition and its use in construction, mortar composition for construction having biomass ashes from agricultural and forestry residues, agro-industrial residues selected from almond shell or cork, resins, a binder selected from calcium oxide or calcium carbonate and water. Such a composition presents environmental advantages by employing residues of different origins in complete substitution of cement and sand, typically used in mortars. The mortar composition of the present invention can be used both in traditional construction and with 3D printers, particularly for masonry and coating.

Claims

1. A mortar composition for construction comprising biomass ashes from agricultural and forestry residues, agro-industrial residues selected from almond shells or cork, resins, a binder selected from calcium oxide or calcium carbonate and water.

2. The mortar composition according to claim 1, wherein the agro-industrial residues are added to the composition in powder form.

3. The mortar composition according to claim 1, wherein the biomass ashes of agricultural and forestry residues are rice straw ashes.

4. The mortar composition according to claim 1, characterized in that the composition further comprises synthetic fibers.

5. The mortar composition according to claim 1, wherein the composition further comprises natural fibers of vegetable, animal or mineral origin.

6. The mortar composition according to claim 1, wherein the composition further comprises metal fibers.

7. The mortar composition according to claim 1, wherein the composition further comprises additives selected from the group comprising plasticizers or superplasticizers, water retention agents, thickeners, biocides, dispersants, water repellent agents, pigments, accelerators and/or retarders, or a mixture thereof.

8. A construction mortar comprising the mortar composition of claim 1.

9. A coating mortar comprising the mortar composition of claim 1.

10. A masonry mortar comprising the mortar composition of claim 1.

Description

DESCRIPTION OF THE INVENTION

[0013] The present invention solves the problems present in the state of the art by providing a mortar composition in which sand and cement are not incorporated, as is traditionally done, but in complete replacement of these component biomass ashes of agricultural and forestry residues and agro-industrial residues such as almond shells or cork are used. This substitution is total, not partial as described in the state of the art.

[0014] Thanks to this new mortar composition, the problem of overexploitation of sand resources and environmental problems associated with CO.sub.2 emissions for the manufacture of cement are solved.

[0015] Additionally, the problem of polluting residues (ash) from agricultural and forestry biomass companies is solved, thanks to its reuse, adapting to the new environmental demands.

[0016] The mortar composition of the present invention adapts to the new construction conditions and trends, such as construction with 3D printers, to adopt the forms that are required in the shortest possible time and as a result, better efficiency and lower costs of construction are achieved thus further reducing the carbon footprint of the works in which it is used.

[0017] In a first aspect, the present invention relates to a mortar composition comprising biomass ash from agricultural and forestry residues, selected agro-industrial residues of almond shell or cork, resins, a binder selected from calcium oxide or calcium carbonate and water.

[0018] In another aspect of the invention, the agro-industrial residues of the mortar composition are added in powder form.

[0019] In another aspect of the invention, the biomass ashes from agricultural and forestry residues in the mortar composition of the present invention are rice straw ashes.

[0020] The resins used can be any type of resin compatible with its final use.

[0021] In another aspect of the invention, the mortar composition further comprises synthetic fibers. Some examples of such fibers are polyvinyl, polypropylene, polyester, nylon, or polyurethane fiber, carbon fiber, or fibers that include carbon nanotubes or graphene.

[0022] In another aspect of the invention, the mortar composition further comprises natural fibers of vegetable, animal or mineral origin. This group includes all those fibers of vegetable origin such as straw fibers from different crops (such as corn, rice or wheat), bamboo fibers, seeds (such as cotton and coconut) or fibers derived from wood. As for the fibers of animal origin, these are extracted from wool, hair, silk and other filaments. On the other hand, mineral fibers include fiberglass and precious metal fibers, such as gold and silver.

[0023] In another aspect of the invention, the mortar composition further comprises metal fibers.

[0024] Said fibers (synthetic, natural and metallic) will be selected based on the final application of the composition.

[0025] In another aspect of the invention, the mortar composition further comprises additives selected from the group comprising plasticizers or superplasticizers, water retention agents, thickeners, biocides, dispersants, water repellent agents, pigments, accelerators and/or retarders, or mixture of them. These additives are incorporated into the composition of the present invention in any compatible form, such as powder, gel or liquid form.

[0026] In another aspect, the present invention relates to the use of the mortar composition, described above, as a construction material.

[0027] In another aspect, the composition can be used as a coating mortar. Said composition can be used as a coating and decoration for all types of walls and sidewalls, both for exteriors and interiors, as well as in new works, reforms or rehabilitations.

[0028] In a final aspect, the composition can be used as a masonry mortar. In other words, the composition can be used for grouting and fixing masonry pieces on walls, pillars and partitions.

DESCRIPTION OF EMBODIMENTS

[0029] Having described the present invention, it is further illustrated by the following example. The purpose of the example set forth below is to illustrate the invention, without thereby limiting its scope.

Example 1

[0030] Specimens were prepared with the mortar composition of the present invention, more specifically, a sample with the following composition: 275 g of biomass ash from forest and agricultural residues, 200 g of almond shells in powder format, 150 g of CaO, 200 g of resin and 250 g of water.

[0031] Subsequently, different tests were carried out with the specimens in accordance with the UNE-EN-1015 standard, relating to masonry mortar tests.

[0032] More specifically, tests were carried out to determine the dry apparent density of the hardened mortar (Standard UNE-EN-1015-10), resistance to bending and compression of the hardened mortar (Standard UNE-EN-1015-11) and absorption coefficient of water by capillarity of the hardened mortars (Standard UNE-EN-1015-18). The values obtained are represented in Table 1.

TABLE-US-00001 TABLE 1 Results obtained in the tests carried out on a sample of the mortar composition of the present invention Property Magnitude Normative UNE Compressive strength (MPa) >5 EN 1015-11 Water absorption by capillarity <0.3 EN 1015-18 (kg/m.sup.2 .Math. min.sup.0.5) Apparent dry density (kg/m.sup.3) <900 EN 1015-10

[0033] Taking into account the values obtained, a classification of the mortar was carried out in accordance with the UNE-EN 998-1 standard, which classifies this material according to its compressive strength and its absorption of water by capillarity. The classification and values are found in table 2.

TABLE-US-00002 TABLE 2 Values and category according to the UNE EN 998-1 standard for the composition of the mortar of the present invention Values of the mortar Cate- Values of the UNE composition of the Property gories EN 998-1 standard present invention Compressive CS I 0.4 MPa-2.5 MPa strength CS II 1.5 MPa-5.0 MPa >5 MPa interval at CS III 3.5 MPa-7.5 MPa 28 days (CS) CS IV ?6 MPa Water W 0 Not specified absorption by W 1 c ? 0.40 kg/m.sup.2 .Math. min.sup.0.5 <0.3 kg/m.sup.2 .Math. min.sup.0.5 capillarity (W) W 2 c ? 0.20 kg/m.sup.2 .Math. min.sup.0.5

[0034] The value of water absorption by capillarity (category W 1) of the mortar composition of the present invention indicates that it can be used as a coating with medium resistance to filtration.

[0035] Taking into account the compressive strength obtained value (see Table 1 or Table 2), and the classification of the UNE-EN 998-2 standard on masonry mortar specifications, the mortar composition of the present invention would be classified as M-5. This classification indicates that the mortar can be used as a common masonry mortar.

[0036] In summary, the obtained results demonstrate that the mortar composition of the present invention has the appropriate physical and chemical properties to be used in construction.

BIBLIOGRAPHIC REFERENCES

[0037] [1] J. Rosell?, L. Soriano, M. P. Santamarina, J. L. Akasaki, J. Monz?, and J. Pay?, Rice straw ash A potential pozzolanic supplementary material for cementing systems, Ind. Crops Prod., vol. 103, pages 39-50, 2017. [0038] [2] Molina Salinas, Javier Eduardo; Eguez, Hugo. Adici?n de ceniza de cascarilla de arroz en hormig?n compactado con rodillo. 2002. Bachelor's thesis. [0039] [3] Gonz?lez, B., et al. Ensayos de hormigones fabricados con polvo de corcho. Building Materials, 2007, vol. 57, no 286, page 83-90. [0040] [4] Bustos, Arturo. Aprovechamiento de residuos org?nicos (c?scara de almendra) para sustituci?n de ?rido grueso en la elaboraci?n de hormig?n convencional. Building Annals, 2016, vol. 2, no 3, page 1-8. [0041] [5] R. Khan, A. Jabbar, I. Ahmad, W. Khan, A. N. Khan, and J. Mirza, Reduction in environmental problems using rice-husk ash in concrete, Constr. Build. Mater., vol. 30, pages 360-365, 2012. [0042] [6] G. Rodriguez De Sensale, Effect of rice-husk ash on durability of cementitious materials, Cem. concr. Compos., vol. 32, no. 9, pages 718-725, 2010. [0043] [7] B. H. Abu Bakar, M. J. Megat Azmi, and P. J. Ramadhansyah, Effect of rice husk ash fineness on the chemical and physical properties of concrete, Mag. concr. Res., Vol. 63, no. 5, pp. 313-320, 2011. [0044] [8] F. Baeza, J. Pay?, O. Galao, J. M. Saval, and P. Garc?s, Blending of industrial waste from different sources as partial substitution of Portland cement in pastes and mortars, Constr. Build. Mater., vol. 66, no. 66, pages 645-653, 2014. [0045] [9] Samantha Elizabeth Hidalgo Astudillo Evaluaci?n de la reactividad puzolanica de la ceniza de paja de arroz. Construction engineering and civil engineering projects. Polytechnic University of Valencia (2018).