MORTAR AND CONSTRUCTION MATERIAL

Abstract

The present invention relates to a mortar with a composition comprising the following components expressed in percentage by weight: 65-69% calcium sulphate; 28-33% water; and 0.01-0.1% polycarboxylic acid-based setting control additive. The invention also relates to a construction material with a composition that consists of a mortar mixture such as the aforementioned mixture and a granular material selected from among ethyl vinyl acetate, cork or marble powder. According to the invention, the construction material can be used to produce construction parts, blocks or panels, and the parts produced with said construction material can be attached to each other and/or coated with the mortar.

Claims

1. A construction material preparation comprising: a mortar preparation, said mortar preparation comprising: about 38-69% by weight of calcium sulfate; about 16-33% by weight of water; about 0.01-1.0% by weight of a setting control additive, said setting control additive comprising polycarboxylic acid; wherein said mortar preparation has an absolute density of about 1000-1450 kg/m.sup.3; and wherein said mortar preparation has a surface density of about 21.75 kg/m.sup.3.

2. The construction material preparation of claim 1, further comprising at least one granular material, said at least one granular material selected from a list of materials comprising ethyl vinyl acetate, cork, and marble powder.

3. The construction material preparation of claim 2: wherein said at least one granular material is ethyl vinyl acetate; wherein said construction material preparation is characterized by a weight ratio of said mortar preparation to said at least one granular material of about 3:7; and wherein said at least one granular material is comprised of a plurality of granules each having a thickness of between about 30-1000 m.

4. The construction material preparation of claim 2: wherein said at least one granular material is cork; wherein said construction material preparation is characterized by a ratio of said mortar preparation to said at least one granular material of about 4:6; and wherein said at least one granular material is comprised of a plurality of granules each having a thickness of between about 30-1000 m.

5. The construction material preparation of claim 2: wherein said at least one granular material is marble powder; wherein said construction material preparation is characterized by a volumetric ratio of said mortar preparation to said at least one granular material of about 3:1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0046] For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

[0047] FIG. 1 shows an image of crushed remains of EVA or EVA rubber.

[0048] FIG. 2 shows a perspective image of a brick-shaped block in which the material added to the mortar is EVA.

[0049] FIG. 3 shows a perspective image of a plate where the material added to the mortar is EVA.

[0050] FIG. 4 shows an image of crushed cork remains.

[0051] FIG. 5 shows a perspective image of a brick-shaped block in which the material added to the mortar is cork.

[0052] FIG. 6 shows a perspective image of a plate where the material added to the mortar is cork.

[0053] Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0054] As previously mentioned, a first aspect of the invention is to define the composition of a possible embodiment of mortar with the following components in percentages by weight: [0055] 67.97% calcium sulfate; [0056] 31.98% water; and [0057] 0.05% setting control additive based on polycarboxylic acid.

[0058] This mortar, for a thickness of 1.5 cm, has 1280 Kg/m.sup.3 of absolute density; and 21.75 Kg/m.sup.3 of surface density, with a pH of 8 and a water solubility value of 0.25.

[0059] A series of test specimens is made with a mortar according to the previous dosage to determine the bending resistance of said material. Table 1 shows the results:

TABLE-US-00001 TABLE 1 Breaking Bending Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 160.2 40.2 40.4 1908 4.50 2 160.2 40.3 41.5 1643 3.85 3 160.1 40.3 40.8 1954 4.60 4 160.4 40.3 40.1 1993 4.70 5 160.3 40.0 40.2 2185 5.15 6 160.2 40.0 39.8 2118 5.00

[0060] The determination is carried out in accordance with UNE-EN13279-2:2014, with the breakage of the specimens being 7 days after curing in the test atmosphere conditions indicated in section 3.1 of the aforementioned standard.

[0061] The average bending resistance result is 4.63 N/mm.sup.2.

[0062] A series of test specimens are made with a mortar according to the previous dosage to determine the compressive strength of said material. Table 2 shows the results:

TABLE-US-00002 TABLE 2 Breaking Compression Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 1.1 75.1 40.2 40.4 20590 12.90 1.2 96.2 40.2 40.3 20784 13.00 2 2.1 94.4 40.3 40.4 21680 13.60 2.2 83.7 40.2 40.3 22106 13.85 3 3.1 81.2 40.2 40.3 21435 13.40 3.2 88.0 40.2 40.5 22267 13.95 4 4.1 78.4 40.1 39.9 24303 15.20 4.2 84.8 40.3 40.5 22564 14.15 5 5.1 76.4 40.1 40.0 22287 13.95 5.2 87.4 40.1 40.5 21660 13.55 6 6.1 75.6 40.1 39.7 23608 14.80 6.2 87.2 40.2 40.3 20357 12.75

[0063] The determination is carried out in accordance with UNE-EN13279-2:2014, with the breakage of the specimens being 7 days after curing in the test atmosphere conditions indicated in section 3.1 of the aforementioned standard.

[0064] The average flexural strength result is 13.78 N/mm.sup.2. It can be seen that the average of the product allows us to obtain a mortar with resistance characteristics superior to the equivalent type M80 cement mortars, and even, in some specimens, resistances practically similar to the type M160 cement mortars are achieved, which is the category of cement mortars with maximum resistant performance.

[0065] Two values are also obtained for determining the setting time, carried out following the UNE-EN13279 standard and according to the knife method. The values obtained are 51 minutes and 38 minutes, and an average setting time of 44 minutes can be determined. This indicates that a mortar executed according to the previous dosage obtains resistant values in a short period of less than 45 minutes.

[0066] Also, as previously mentioned, a second aspect of the invention is to define a construction material from said mortar. This construction material is formed by mixing mortar and a granular material selected from EVA, recycled cork, or marble powder.

[0067] In a possible embodiment of the invention, the material added to the mortar is EVA, ethylene vinyl acetate or EVA rubber. This material is used crushed, and allows the reuse of remains of this material that in normal use is neither reusable nor recyclable. See FIG. 1. The construction material has a weight ratio of mortar and EVA of 3:7, where the EVA has 0.5 mm thick granules.

[0068] A series of test specimens are made with a sample of a brick-type construction block according to the previous dosage (see FIG. 2) to determine the bending resistance of said block. Table 3 shows the results:

TABLE-US-00003 TABLE 3 Breaking Bending Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 160.3 40.8 39.1 503 1.20 2 160.2 41.5 40.1 485 1.15 3 160.6 41.3 41.6 526 1.25

[0069] The determination is carried out according to UNE-EN13279-2:2014, with the breakage of the specimens being 28 days after curing at room temperature.

[0070] The average bending resistance result is 1.20 N/mm.sup.2.

[0071] A series of test tubes is made with a sample of a block according to the previous dosage to determine the compressive strength of said block. Table 4 shows the results:

TABLE-US-00004 TABLE 4 Breaking Compression Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 1.1 84.6 41.0 39.9 3152 2.10 1.2 84.9 41.0 39.6 2812 2.00 2 2.1 83.3 41.1 40.1 2896 2.00 2.2 81.7 42.0 40.3 3306 2.20 3 3.1 78.7 40.1 41.7 3167 2.15 3.2 85.6 41.6 40.6 3093 2.05

[0072] The determination is carried out according to UNE-EN13279-2:2014, with the breakage of the specimens being 28 days after curing at room temperature.

[0073] The average bending resistance result is 2.06 N/mm.sup.2. It can be seen that the average of the product allows us to obtain a block with resistance greater than 2 N/mm.sup.2, the minimum for this type of construction parts.

[0074] Tests are also carried out for some samples of a panel executed according to the previous dosage (see FIG. 3), to determine the bending resistance of said panel. Table 5 shows the results:

TABLE-US-00005 TABLE 5 Breaking Bending Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 160.2 40.3 40.2 2205 5.20 2 160.6 40.7 41.0 2524 5.95 3 160.7 41.1 40.9 2373 5.60

[0075] The determination is carried out according to UNE-EN13279-2:2014, with the breakage of the specimens being 28 days after curing at room temperature.

[0076] The average bending resistance result of the aforementioned panel is 5.60 N/mm.sup.2.

[0077] A series of test tubes is made with a sample of a panel according to the previous dosage to determine the compression resistance of said panel. Table 6 shows the results:

TABLE-US-00006 TABLE 6 Breaking Compression Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 1.1 84.2 39.8 40.3 27835 17.40 1.2 84.3 40.0 40.2 25669 16.05 2 2.1 79.8 40.6 40.6 23381 14.65 2.2 89.0 40.5 40.7 27867 17.45 3 3.1 76.4 41.6 40.7 27581 17.25 3.2 89.8 40.5 41.1 20079 12.55

[0078] The determination is carried out according to UNE-EN13279-2:2014, with the breakage of the test pieces being 28 days after curing at room temperature.

[0079] The average compressive strength result is 15.9 N/mm.sup.2. It can be seen that the average of the product allows us to obtain a panel with resistance greater than 5 N/mm.sup.2, the minimum for this type of construction elements.

[0080] In another possible embodiment of the invention, the material added to the mortar is cork. This material is used crushed, and allows the use of remains of this material left over from the industry related to cork. See FIG. 4. The construction material has a weight ratio of mortar and cork of 4:6, where the cork is made up of 0.5 mm thick granules.

[0081] A series of test specimens are made with a sample of a brick-type construction block according to the previous dosage (see FIG. 5) to determine the bending resistance of said block. Table 7 shows the results:

TABLE-US-00007 TABLE 7 Breaking Bending Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 160.0 40.1 41.5 678 1.60 2 159.9 40.0 41.3 614 1.45 3 160.0 40.2 41.3 691 1.65

[0082] The determination is carried out according to UNE-EN13279-2:2014, with the breakage of the specimens being 28 days after curing at room temperature.

[0083] The average bending resistance result is 1.60 N/mm.sup.2.

[0084] A series of test tubes is made with a sample of a block according to the previous dosage to determine the compression resistance of said block. Table 8 shows the results:

TABLE-US-00008 TABLE 8 Breaking Compression Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 1.1 78.2 42.7 40.0 4872 3.05 1.2 85.8 40.4 40.0 4815 3.05 2 2.1 78.3 41.8 40.1 4359 2.75 2.2 83.7 40.4 40.1 4703 2.95 3 3.1 79.3 40.5 40.1 4603 2.90 3.2 83.1 42.0 40.1 4600 2.90

[0085] The determination is carried out according to UNE-EN13279-2:2014, with the breakage of the specimens being 28 days after curing at room temperature.

[0086] The average flexural strength result is 2.9 N/mm.sup.2. It can be seen that the average of the product allows us to obtain a block with resistance greater than 2 N/mm.sup.2, the minimum for this type of constrictive pieces.

[0087] Tests are also carried out for some samples of a panel executed according to the above dosage (see FIG. 8), to determine the flexural resistance of said panel. Table 9 shows the results:

TABLE-US-00009 TABLE 9 Breaking Bending Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 160.2 40.3 40.2 2205 5.20 2 160.6 40.7 41.0 2524 5.95 3 160.7 41.1 40.9 2373 5.60

[0088] The determination is carried out according to UNE-EN13279-2:2014, with the breakage of the specimens being 28 days after curing at room temperature.

[0089] The average bending resistance result of the aforementioned panel is 5.60 N/mm.sup.2.

[0090] A series of test tubes is made with a sample of a panel according to the previous dosage to determine the compression resistance of said panel. Table 10 shows the results:

TABLE-US-00010 TABLE 10 Breaking Compression Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 1.1 77.4 40.6 41.2 28822 18.05 1.2 85.4 40.2 41.0 30736 19.25 2 2.1 76.9 39.9 40.9 27076 16.95 2.2 84.7 39.5 41.2 30103 18.85 3 3.1 75.9 40.8 41.2 29620 18.55 3.2 85.7 40.7 40.9 27580 17.25

[0091] The determination is carried out according to UNE-EN13279-2:2014, with the breakage of the specimens being 28 days after curing at room temperature.

[0092] The average compressive strength result is 18.2 N/mm.sup.2. It can be seen that the average of the product allows us to obtain a panel with resistance greater than 5 N/mm.sup.2, the minimum for this type of construction elements.

[0093] In another possible embodiment of the invention, the material added to the mortar is marble powder. This material is obtained as waste material in marble quarries where the construction material has a proportion of mortar and marble powder of 3 m.sup.3:1 m.sup.3.

[0094] A series of test specimens are made with a sample of a brick-type construction block according to the previous dosage to determine the bending resistance of said block. Table 11 shows the results:

TABLE-US-00011 TABLE 11 Breaking Bending Test Length Width Thickness Load Resistance Subject (mm) (mm) (mm) (N) (MPa) 1 160.0 39.78 37.07 1041 3.56 2 160.0 38.52 41.33764 1194 3.28 3 160.0 39.69 41.33924 1455 3.57 4 160.0 39.46 36.99 1261 3.50 5 160.0 37.48 39.82 1264 3.19 6 160.0 39.79 40.50 1522 3.50 7 160.0 40.48 39.42 1445 3.45 8 160.0 39.88 39.42 1296 3.14 9 160.0 39.31 36.91 1141 3.20 10 160.0 40.07 39.73 1412 3.35 11 160.0 39.26 37.96 1129 2.99 12 160.0 39.10 38.19 1163 3.06

[0095] The determination is made according to UNE-EN13279-2:2014. The average flexural strength result is 3.32 N/mm.sup.2, already higher than the minimum values for compressive strength of 2 N/mm.sup.2, and also higher than the values obtained in some of the previous tests. Additionally, average density values of 1546.50 Kg/m.sup.3 are obtained.

[0096] Since many modifications, variations and changes in detail can be made to the described embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.