ULTRA-HIGH PERFORMANCE NON-SELF-CONSOLIDATING CONCRETE

Abstract

A hydraulic binder includes in mass percent from 20 to 82% of a Portland cement the particles of which have a D.sub.50 comprised from 2 m to 11 m; from 15 to 56% of a non-pozzolanic mineral addition A1, the particles of which have a D.sub.50 from 1 to 150 m and selected from among limestone additions, siliceous additions, siliceous limestone mineral additions, calcined shales, zeolites, burnt plant ashes, and mixtures thereof; from 4 to 30% of pozzolanic mineral addition A2, the particles of which have a D.sub.50 from 1 to 150 m; a sum of the percentages of the Portland cement, the non-pozzolanic mineral addition A1 and the pozzolanic mineral addition A2 being comprised from 90 to 100%.

Claims

1. A hydraulic binder comprising in mass percent: from 20 to 82% of a Portland cement the particles of which have a D.sub.50 comprised from 2 m to 11 m; from 15 to 56% of a non-pozzolanic mineral addition A1, the particles of which have a D.sub.50 comprised from 1 to 150 m and selected from among limestone additions, siliceous additions, siliceous limestone mineral additions, calcined shales, zeolites, burnt plant ashes, and mixtures thereof; from 4 to 30% of pozzolanic mineral addition A2, the particles of which have a D.sub.50 comprised from 1 to 150 m; a sum of the percentages of the Portland cement, the non-pozzolanic mineral addition A1 and the pozzolanic mineral addition A2 being comprised from 90 to 100%.

2. The hydraulic binder according to claim 1, wherein the cement is a CEM I cement.

3. The hydraulic binder according to claim 1, further comprising calcium sulfate.

4. The hydraulic binder according to claim 1, wherein the mineral addition A2 is selected from among silica fume, micro-silica, pozzolanic materials, metakaolin, slags, optionally milled, or mixtures thereof.

5. The hydraulic binder according to claim 1, wherein the particles of the cement have a D.sub.90 comprised from 8 m to 40 m.

6. A mixture comprising in volume percent, at least 43% of the hydraulic binder according to claim 1 and at least 30% of sand, a sum of the percentages of the hydraulic binder and the sand being comprised from 95 to 100%.

7. The mixture according to claim 6, further comprising a sand the particles of which have a D.sub.10 comprised from 100 m to 1 mm, a D.sub.50 comprised from 200 m to 3 mm and a D.sub.90 from 300 m to 5 mm.

8. The mixture according to claim 7, wherein the sand is a siliceous sand or a calcined bauxite sand or mixtures thereof.

9. A hydraulic composition comprising in a volume of 1 m.sup.3 excluding entrained air from 140 to 246 kg of water; and at least 654 liters of mixture according to claim 5; a sum of the volumes of the water and the mixture being comprised from 900 to 1,000 liters.

10. The hydraulic composition according to claim 9 comprising an antifoaming agent.

11. The hydraulic composition according to claim 9, further comprising mineral fibers (glass, basalt), organic fibers (plastic of the PVA type) or metal fibers (steel) or a mixture thereof.

12. A shaped object for the field of building comprising the hydraulic binder according to claim 1.

13. The hydraulic binder according to claim 1, wherein the limestone additions include calcium carbonate.

14. The hydraulic binder according to claim 1, wherein the siliceous additions include quartz.

15. A shaped object for the field of building comprising the mixture according to claim 6.

Description

EXAMPLES

[0137] The present invention is described by the examples A, B, C, D, E, F, G, H which follow, which are non-limiting.

[0138] Raw Materials:

TABLE-US-00001 Cement 52.5N PMES Le Teil Lafarge France LHY-4521-1, LHY-4815 and LHY-4521 Cement 52.5 Sagunto Lafarge Spain LHY-4845 Cement 52.5 Villaluenga Lafarge Spain LHY-4729 Metakaolin Metamax (MK) BASF, USA Superpozz (SPzz) Lafarge, South Africa Millisil C6 Sibelco, France Durcal 1 (D1) Omya, France Shrinkage reducing agent (SRA) BASF, USA Silica fume MST02 Le Pontet SEPR, France Anhydrite Micro A Maxit, France Sand no. 1 BE01 Sibelco, France Sand no. 2 PE2LS Fulchiron, France Sand no. 3 Betsinor Betsinor, France Superplasticizer F2 Chryso, France Prelom (PL) BASF, France

[0139] The cements were prepared by milling and separation of Portland cement CEM I 52.5 stemming from identified cement works. This milling was carried out by using an air jet milling machine associated with a very high efficiency separator. The obtained milled cements had a D.sub.10, a D.sub.50, a D.sub.90, a Blaine specific surface area (SSB) and a BET specific surface area as mentioned in table I below.

TABLE-US-00002 TABLE I D.sub.10 D.sub.50 D.sub.90 SSB BET Batch size Cement 52, 5N 1.92 7.98 18.09 5520 1.6 LHY-4521-1 PMES Le Teil 1.75 8.00 22.21 5110 3.09 LHY-4815 1.86 11.75 36.20 n.d. 1.35 LHY 4521 Cement 52.5 Sagunto 1.63 8.56 25.10 5950 2 LHY-4845 Cement 52.5 1.35 5.72 14.62 7240 2.55 LHY-4729 Villaluenga

[0140] Le Millisil C6 is a siliceous filler (quartz) from Sibelco. It corresponds to the A1 addition. It has a D.sub.10 of 2.9 m, a D.sub.50 of 28.9 m, and a D.sub.90 of 95.6 m.

[0141] The silica fume 980 NS from SEPR, is characterized by a BET specific surface area of 13 m.sup.2/g and by a D.sub.50 of 4.24 m. It corresponds to the addition A2.

[0142] Metamax metakaolin is characterized by a BET specific surface area of 11.8 m.sup.2/g and by a D.sub.50 of 4.37 m.

[0143] Superpozz is a pozzolan from Lafarge and characterized by a BET specific surface area of 1.05 m.sup.2/g and by a D.sub.50 of 5 m.

[0144] The Micro A anhydrite is a micronized anhydrous calcium sulfate from Maxit. It has a D.sub.10 of 1.6 m, a D.sub.50 of 12.3 m, and a D.sub.90 of 17.0 m.

[0145] The sand no. 1 BE01 is a siliceous sand from Sibelco. It has a D.sub.10 of about 210 m and a D.sub.50 of about 310 m, a D.sub.90 of about 400 m.

[0146] The sand no. 2 is a siliceous sand from Fulchiron. It has a D.sub.10 of about 60 m and a D.sub.50 of about 150 m, a D.sub.90 of about 250 m.

[0147] The sand no. 3 is a siliceous sand from Betsinor. It has a D.sub.10 of about 170 m and a D.sub.50 of about 245 m, a D.sub.90 of about 350 m.

[0148] The superplasticizer F2 is a new generation superplasticizer based on modified polycarboxylate, the dry extract concentration of which is 29.51%, a mass percentage.

[0149] The Prelom superplasticizer is based on modified polycarboxylic ether, this is the Prelom 300 from BASF, the dry extract concentration of which is 15%, a mass percentage.

[0150] Equipment: [0151] a kneader-mixer RAYNERI R601, which was provided by VMI with a tank of 10 liters. This kneader exerts a planetary rotary movement; [0152] cylindrical cardboard molds with a diameter of 7 cm and a height of 14 cm; [0153] a weathering chamber with 95-100% relative hygrometry and 90 C.+/1 C. provided by Verre Labo Mula; [0154] a humid chamber with 95-100% relative hygrometry and 20+/1 C.

[0155] Procedure for Preparing the Hydraulic Composition According to the Invention:

[0156] The concrete (hydraulic composition) was manufactured according to the procedure described hereafter: [0157] 1) introduction of the dry materials (sand, A1, cement, calcium sulfate and silica fume) in the bowl of the Rayneri kneader; [0158] 2) kneading for 60 seconds at the rate of 15 revolutions per minute, for homogenizing the dry materials; [0159] 3) introduction of the mixing water and of the super-plasticizer for 30 seconds, at the speed of rotation of 15 revolutions per minute; [0160] 4) kneading for 1 minute at the speed of 15 revolutions per minute; [0161] 5) kneading for 3 minutes and 30 seconds at the speed of 45 revolutions per minute.

[0162] A fresh concrete was obtained. The concrete was cast into cylindrical molds. The obtained molded specimens are hermetically closed and are pending for 24 hours at 20 C. Next, the specimens are removed from the mold and are either placed: [0163] in a humid chamber for 28 days at 20 C. and 100% of relative humidity; or [0164] in a humid chamber for 7 days at 20 C. and 100% relative humidity, and then in a weathering chamber for 48 h at 90 C. and 100% relative humidity (heat treatment).

[0165] The mechanical strengths were then measured. [0166] Hydraulic binders according to the invention, in % by mass, based on the total binder mass:

TABLE-US-00003 F01 F02 F03 F04 F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 % 0.34 0.34 0.42 0.49 0.43 0.34 0.34 0.40 0.39 0.34 0.34 0.42 0.26 0.40 0.34 ce- ment Batch LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- of 4845 4845 4845 4845 4845 4845 4845 4845 4845 4845 4845 4845 4845 4845 4845 ce- ment Na- 980 980 980 980 980 980 980 980 980 980 980 980 980 ture NS NS NS NS NS NS NS NS NS NS NS NS NS A2 Na- MK SPzz SPzz MK ture A2 Na- C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 ture A1 Na- D1 ture A1 % A2 0.17 0.17 0.18 0.06 0.07 0.17 0.17 0.04 0.20 0.17 0.16 0.18 0.26 0.23 0.16 % A1 0.48 0.48 0.37 0.43 0.48 0.48 0.48 0.55 0.39 0.48 0.48 0.37 0.47 0.34 0.48 Ad- 0.05 0.05 0.05 0.06 0.12 0.07 0.06 0.07 0.04 0.04 0.03 0.06 0.06 0.04 mix- ture PL Ad- 0.04 mix- ture F2 Ad- mix- ture SRA % 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.01 0.02 0.02 An- hy- drite Total 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 % 0.34 0.37 0.34 0.42 0.35 0.34 0.35 0.34 0.34 0.34 0.34 0.35 0.35 0.34 ce- ment Batch LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- LHY- of 4845 4845 4845 4845 4521 4729 4521 4815 4845 4815 4845 4521 4521 4521-1 ce- ment Na- 980 980 980 980 980 980 980 980 980 980 980 980 ture NS NS NS NS NS NS NS NS NS NS NS NS A2 Na- MK SPzz SPzz ture A2 Na- C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 C6 ture A1 Na- D1 ture A1 % A2 0.16 0.09 0.16 0.18 0.17 0.16 0.17 0.17 0.16 0.17 0.17 0.17 0.17 0.17 % A1 0.48 0.52 0.48 0.37 0.49 0.48 0.49 0.48 0.49 0.48 0.48 0.49 0.49 0.48 Ad- 0.04 0.04 0.04 0.04 0.05 0.04 0.04 0.03 0.04 0.03 0.04 0.08 0.03 0.03 mix- ture PL Ad- mix- ture F2 Ad- 0.02 0.06 0.06 mix- ture SRA % 0.02 0.02 0.02 0.02 0.00 0.01 0.00 0.01 0.01 0.01 0.01 0.00 0.00 0.01 An- hy- drite Total 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 [0167] Composition of the mixtures according to the invention, in % by volume:

TABLE-US-00004 F01 F02 F03 F04 F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 % 50 51 51 51 48 51 51 48 49 51 51 51 51 44 52 Binder % 50 49 49 49 52 49 49 52 51 49 49 49 49 56 48 Sand Sand 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 No. F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 % 48 48 51 51 48 51 53 51 51 51 51 51 51 51 Binder % 52 52 49 49 52 49 47 49 49 49 49 49 49 49 Sand Sand 1 1 1 1 3 1 3 1 1 1 1 2 1 1 No. [0168] Hydraulic compositions according to the invention, in liters for 1 m.sup.3 of concrete except entrained air: The hydraulic compositions hereafter are non-self-setting, according to the invention.

TABLE-US-00005 F01 F02 F03 F04 F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 Mix- 819 765 768 769 755 796 792 775 776 769 763 761 795 777 774 ture in liters Mix- 2192 2056 2074 2109 2060 2131 2128 2116 2111 2068 2052 2056 2111 2087 2082 ture in kg Ad- 13.85 16.98 24.09 26.70 26.66 45.56 26.78 25.01 29.50 13.06 12.91 15.71 15.73 21.66 14.27 mix- ture Add- 181.1 220.9 211.5 208.0 222.4 165.7 184.8 204.1 198.8 220.1 226.2 226.1 191.2 205.0 214.0 ed water Total 181.1 235.3 232.0 230.7 245.1 204.4 207.5 225.3 223.8 231.2 237.1 239.4 204.5 223.5 226.2 water F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 Mix- 778 773 783 772 783 780 774 788 792 795 797 784 792 794 ture in liters Mix- 2091 2092 2105 2088 2077 2045 2004 1997 2001 1931 1912 1904 1929 1937 ture in kg Ad- 14.18 14.30 13.72 17.02 16.56 15.14 14.86 18.02 15.13 30.75 32.51 25.37 10.28 8.58 mix- ture Add- 209.7 215.1 205.7 213.2 202.6 207.1 213.2 202.7 195.1 196.3 192.9 194.6 199.6 198.5 ed water Total 221.8 227.3 217.4 227.6 216.7 220.0 225.8 212.0 208.0 205.0 203.2 216.1 208.4 205.8 water [0169] Performances of the hydraulic compositions:
The compressional mechanical strengths are measured on a cylinder of diameter 70 mm and of height 140 mm, i.e. at 28 days or after a heat treatment (HT) at 90 C. The results are expressed in MPa.

TABLE-US-00006 F01 F02 F03 F04 F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 Threshold 30 115 110 180 100 20 100 70 30 in Pa Resistance 117.9 130.5 143.3 124.1 118.8 162.9 152.2 96.6 119.2 after HT* in MPa Resistance 104.9 94.1 113.9 98.3 98.1 96.9 at 28 days in MPa F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 Threshold 263 115 in Pa Resistance 113.62 125.24 131.63 103 145.9 after HT* in MPa Resistance 109.4 102.8 95.1 122 106.36 114.01 109.59 98.18 101.76 136 113.9 at 28 days in MPa *Heat treatment