QUICK-DRYING LIGHTWEIGHT FILL

Abstract

A single- or two-component mortar composition including i) an aluminate binder, ii) a calcium sulfate binder, iii) one or more fillers with a raw density of at least 2.0 g/cm3, and iv) one or more lightweight fillers with a raw density of less than 1.5 g/cm3, wherein the quantity of lightweight filler equals 30 to 70 wt. %, the total quantity of aluminate binder and calcium sulfate binder equals 20 to 65 wt %, and the weight ratio of aluminate binder to calcium sulfate binder ranges from 1:1 to 1:10. When used, the mortar composition hardens quickly and is suitable as a lightweight fill for producing floor structures on substrates with a limited load-bearing capacity.

Claims

1. A one- or two-component mortar composition comprising i) an aluminate binder selected from calcium aluminate cement and/or calcium sulfoaluminate cement, ii) a calcium sulfate binder selected from calcium sulfate hemihydrate and/or calcium sulfate anhydrite, iii) one or more fillers having a particle density of at least 2.0 g/cm.sup.3, and iv) one or more lightweight fillers, having a particle density of less than 1.5 g/cm.sup.3, wherein the amount of lightweight filler, having a particle density of less than 1.5 g/cm.sup.3 is 30% to 70% by weight and the total amount of aluminate binder and calcium sulfate binder is 20% to 65% by weight, the weight ratio of aluminate binder to calcium sulfate binder being in the range from 1:1 to 1:10, the weight information being based on the dry weight of the mortar composition.

2. The one- or two-component mortar composition as claimed in claim 1, wherein the content of lightweight filler, having a particle density of less than 1.5 g/cm.sup.3 is 35% to 65% by weight, based on the dry weight of the mortar composition.

3. The one- or two-component mortar composition as claimed in claim 1, wherein the one or more lightweight fillers having a particle density of less than 1.5 g/cm.sup.3 are selected from expanded glass, hollow glass spheres, foam glass ballast, hollow aluminum silicate spheres, pumice, expanded clay, expanded shale, expanded perlite, recycled aggregate, non-expanded perlites, hollow silicatic microspheres, recycled plastic, ground rubber, biobased lightweight fillers, based on hemp, rice husks, wood or cork, or combinations thereof.

4. The one- or two-component mortar composition as claimed in claim 1, wherein the one or more lightweight fillers having a particle density of less than 1.5 g/cm.sup.3, have a mean grain size in the range from 0.05 to 16 mm.

5. The one- or two-component mortar composition as claimed in claim 1, wherein the content of filler having a particle density of at least 2.0 g/cm.sup.3 is 2% to 20% by weight, based on the dry weight of the mortar composition.

6. The one- or two-component mortar composition as claimed in claim 1, wherein the one or more fillers having a particle density of at least 2.0 g/cm.sup.3 comprise sand and/or calcium carbonate, the calcium carbonate being chalk and/or limestone flour.

7. The one- or two-component mortar composition as claimed in claim 1, wherein the total amount of aluminate binder and calcium sulfate binder is 20% to 60% by weight, based on the dry weight of the mortar composition, and/or the mortar composition further comprises at least one additive selected from a lithium salt, at least one retarder selected from tartaric acid or a tartaric acid salt, a gluconate, and citric acid or a citric acid salt, a plasticizer, or a combination thereof.

8. A screed comprising the one- or two-component mortar composition as claimed in claim 1.

9. A floor construction comprising, in this order, a first screed layer comprising the one- or two-component mortar composition as claimed in claim 1, a reinforcement layer and a second screed layer, there being optionally a floor covering arranged over the second screed layer.

10. A floor renovation and/or a wood substrate or a multi-layer substrate comprising a wood layer, comprising a layer comprising the one- or two-component mortar composition as claimed in claim 1.

11. A method for producing a floor construction on a substrate, comprising a) applying a mixture of the mortar composition as claimed in claim 1 with water to the substrate, to form a first screed layer, b) applying a reinforcement layer to the first screed layer, c) applying a mixture of a leveling compound with water to the reinforcement layer, to form a second screed layer, and d) optionally applying a floor covering to the second screed layer.

12. The method as claimed in claim 11, wherein the reinforcement layer comprises a sheetlike textile carrier, and/or the leveling compound is a calcium sulfate filling compound, the calcium sulfate filling compound comprising a calcium sulfate binder.

13. The method as claimed in claim 11, wherein the first screed layer has a layer thickness in the range from 15 to 100 mm, and/or the second screed layer has a layer thickness in the range from 6 to 50 mm.

14. A floor construction on a substrate, comprising in this order a first screed layer comprising the mortar composition as claimed in claim 1, a reinforcement layer and a second screed layer, there being optionally a floor covering arranged over the second screed layer.

15. The floor construction as claimed in claim 14, obtainable by a method comprising: a) applying a mixture of the mortar composition with water to the substrate, to form a first screed layer, b) applying a reinforcement layer to the first screed layer, c) applying a mixture of a leveling compound with water to the reinforcement layer, to form a second screed layer, and d) optionally applying a floor covering to the second screed layer.

Description

WORKING EXAMPLES

Example 1

Mortar Composition

[0160] A two-component mortar composition was produced from the components A and B according to the following formulations.

TABLE-US-00001 Component A Parts by weight Calcium sulfoaluminate (i.tech ALI CEM Binder 23.78 GREEN) alpha-Calcium sulfate hemihydrate Binder 61.846 CaCO.sub.3, grain size: D50: 2.2 m Filler 12.282 Calcium sulfate dihydrate 1.307 Vinyl acetate-ethylene copolymer, Redispersible 0.5 98% solids, minimum film-forming powder temperature 4 C. (DIN ISO 2115) Lithium carbonate Accelerator 0.014 Potassium sodium tartrate Retarder 0.105 Sodium gluconate powder Retarder 0.116 Polycarboxylate ether with polyethylene Plasticizer 0.05 glycol side chains Total 100

TABLE-US-00002 Component B Expanded glass, grain size 2-4 mm, 100 particle density: about 0.32 g/cm.sup.3

[0161] Component A and component B were mixed in a ratio of 50% by weight of component A and 50% by weight of component B. The mortar composition obtained had the following composition.

TABLE-US-00003 Mortar composition Parts by weight Calcium sulfoaluminate (i.tech ALI CEM Binder 11.89 GREEN) alpha-Calcium sulfate hemihydrate Binder 30.922 CaCO.sub.3, grain size: D50: 2.2 m Filler 6.141 Calcium sulfate dihydrate 0.654 Vinyl acetate-ethylene copolymer, Redispersible 0.25 98% solids, minimum film-forming powder temperature 4 C. (DIN ISO 2115) Lithium carbonate Accelerator 0.007 Potassium sodium tartrate Retarder 0.053 Sodium gluconate powder Retarder 0.058 Polycarboxylate ether with polyethylene Plasticizer 0.025 glycol side chains Expanded glass, grain size 2-4 mm, 50 particle density: about 0.32 g/cm.sup.3 Total 100

Example 2 and Comparative Example 1

[0162] With the mortar composition of Example 1, a floor construction was produced on a plasterboard as substrate (alternatively a concrete substrate) in the following manner (Example 2): [0163] mixing mortar composition of Example 1 with water (ratio 100 kg mortar composition/16.4 l water) [0164] applying the mixture to the substrate in the layer thickness specified in Table 1 [0165] placing on an armored fabric (woven glass fiber fabric) about 2 hours after applying the mixture and fixing with calcium sulfate filling compound [0166] applying a leveling compound (calcium sulfate filling compound) to the fabric after around 2 hours, layer thickness around 8 mm

[0167] Using a commercially available cement-based dry mortar for lightweight fills (containing lightweight expanded polystyrene aggregate), a floor construction was produced on a gypsum board as substrate in the following manner

Comparative Example 1

[0168] mixing dry mortar with water (ratio 100 kg dry mortar/47.6-52.4 l water) [0169] applying the mixture to the substrate in the layer thickness specified in Table 1 [0170] placing on a glass fiber nonwoven about 4 hours after applying the mixture [0171] applying a cementitious thin coat to the nonwoven after around 48 hours, layer thickness around 8 mm

[0172] The properties of the floor constructions according to Example 2 and Comparative Example 1 were tested. The results are shown in Table 1. The tests were carried out on the mortar composition of the invention (Fill in Table 1) or on the entire floor construction (System in Table 1).

[0173] The following test methods were used: [0174] Particle density: in accordance with DIN EN 1015-10 [0175] Flexural tensile strength/Compressive strength: in accordance with DIN EN 13892-2 [0176] Chair roll tester: in accordance with ASTM C627 [0177] Adhesive tensile strength: in accordance with DIN EN 13892-8 [0178] Pot life 2:20 min after mixing of the mortar composition of Example 2 or the dry mortar of Comparative Example 1 with water, a small area was produced with the mixture every 5 min and tested the next day with a hammer blow. When surface crumbles: end of pot life (end of PL)

TABLE-US-00004 TABLE 1 Layer Comparative Test method Storage Fill System thickness Example 2 example 1 Unit Pot life 45 min >240 min Drying Dry moisture 40 C. 2 h x 20 mm 7.7 still fresh % 6 h x 4.1 23.25 % 1 d x 0.75 13.6 % 2 d x 0.6 5.8 % 2 h x 100 mm 7.62 still fresh % 6 h x 5.92 29.14 % 1 d x 4.82 22.14 % 2 d x 4.38 18.42 % 6 h x 32 mm + 8 mm 4.41 8.43 % 1 d x (prism) 2.92 6.49 % 7 d x 0.82 3.2 % Particle density (determined on prism) Particle density 2 h x 40 mm 0.41 still soft kg/dm.sup.3 6 h x 0.41 still soft kg/dm.sup.3 1 d x 0.41 0.35 kg/dm.sup.3 7 d x 0.41 0.35 kg/dm.sup.3 28 d x 0.41 0.35 kg/dm.sup.3 Flexural tensile/compressive strengths FT/C prism 2 h x 40 mm 0.22/0.89 not measurable N/mm.sup.2 6 h x 0.41/1.33 not measurable N/mm.sup.2 1 d x 0.59/1.81 0.15/0.28* N/mm.sup.2 7 d x 0.74/1.93 0.40/0.38 N/mm.sup.2 28 d x 0.71/1.90 0.43/0.42 N/mm.sup.2 FT Prism 6 h x 40 mm 1.2 0.4 N/mm.sup.2 1 d x 1.2 0.5 N/mm.sup.2 7 d x 1.3 0.7 N/mm.sup.2 28 d x 1.5 0.7 N/mm.sup.2 Chair roll tester in accordance with ASTM C627 Chair roll tester 2 d x 20 mm System structures were resistant to the effect 7 d x up to the last load class. The only difference 2 d x 100 mm was that for Comparative Ex. 1, longer waiting 7 d x times until loading had to be observed. Adhesive tensile strength ATS drilled 1 d x 20 mm + 8 mm 0.38 border 0.46 in the N/mm.sup.2 fabric + in the screed screed ATS not drilled 1 d x 0.81 surface + 0.93 border N/mm.sup.2 in SpMa nonwoven ATS drilled 7 d x 0.60 in the 0.49 in the N/mm.sup.2 screed screed ATS not drilled 7 d x 1.10 surface + 1.00 in N/mm.sup.2 in SpMa SpMa Pot life 2 End of PL x 20 mm 45 >130 min *prisms too soft; SpMa = filling compound