Noise reducing mortar composition

Abstract

A mortar composition, in particular a leveling mortar composition, including: a) 10-50 wt. % of a hydraulic binder, b) 10-25 wt. % of lightweight aggregates, c) 30-50 wt. % of further aggregates which have a particle density that is higher than the particle density of the lightweight aggregates, d) 0.5-5 wt. % of a polymer.

Claims

1. A mortar composition, comprising: 15-40 wt. %, of calcium aluminate cement and/or sulphoaluminate cement; 3-18 wt. %, Portland cement; optionally 0.1-10 wt. % latent hydraulic and/or pozzolanic binder materials, especially slag and/or fly ash; 10-25 wt. % of lightweight aggregates, comprising porous inorganic particles and/or hollow inorganic particles; 30-50 wt. % of further aggregates which have a particle density that is higher than the particle density of the lightweight aggregates, and which aggregates comprise quartz, sand and/or calcium carbonate; 0.5-5 wt. % of a polymer which is a water soluble or water redispersible polymer; and 0-10 wt. %, of one or more additives; whereby all amounts are with respect to the total weight of the mortar composition in dry state, and wherein the mortar composition comprises Portland cement and aluminate cement and/or sulphoaluminate cement with a weight ratio of Portland cement to aluminate cement and/or sulphoaluminate cement from 0.05-3.

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

3. The mortar composition according to claim 1, wherein the lightweight aggregates include two different types of particles, wherein a first type of particles have a particle size of 0.01-1,000 m, and a second type of particles have a particle size of 0.01-4,000 m.

4. The mortar composition according to claim 3, wherein a first type of particles are hollow silicate spheres and the second type of particles are expanded clay aggregates.

5. The mortar composition according to claim 4, wherein a weight ratio of the first type of particles to the second type of particles is from 1:2-10:1.

6. 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 of 45-10 C.

7. A kit-of-parts comprising: (i) a mortar composition according to claim 1; (ii) optionally mineral wool, slag wool and/or glass wool; (iii) optionally, an adhesive composition, whereby the adhesive composition comprises: a) 10-50 wt. % of a hydraulic binder, b) 20-60 wt. % of lightweight aggregates, c) 10-25 wt. % of a polymer; and whereby the adhesive composition is chemically different from the mortar composition; whereby, in addition to the mortar composition, the kit-of-parts comprises either mineral wool, or the adhesive composition, or both.

8. The kit-of-parts according to claim 7, whereby the mineral wool is present in the form of a flat plate or mat.

9. A structure, a wall or a ceiling, comprising: a substrate; a first layer, comprising mineral wool; a second layer, comprising the mortar composition according to claim 1 in hardened state; optionally, a third layer, comprising an adhesive in hardened state, the adhesive composition comprising: a) 10-50 wt. % of a hydraulic binder, b) 20-60 wt. % of lightweight aggregates, c) 10-25 wt. % of a polymer; optionally, a cover element.

10. The structure according to claim 9, whereby a thickness of the first layer is smaller than a thickness of the second layer and/or whereby a thickness of the third layer is smaller than a thickness of the first layer.

Description

EXEMPLARY EMBODIMENTS

(1) 1. Mortar Compositions

(2) Table 1 shows three mortar compositions M1-M3. The mortar compositions have been prepared by intermixing all of the components in dry state. The mortar composition M1-M3 are present as dry powders.

(3) TABLE-US-00001 TABLE 1 Mortar compositions Component M1 M2 M3 Hydraulic binder [wt. %] Portland cement (CEM I, 52.5R) 7 7 7 Calcium sulphoaluminate cement.sup.1) 28 28 28 Lightweight aggregates [wt. %] Hollow alumina-silicate spheres.sup.2) 10 14 18 Expanded clay.sup.3) 6 5 4 Expanded glass.sup.4) 2 Vermiculite.sup.5) 1.5 1.5 1.5 Further aggregates [wt. %] Sand 44.3 37.8 34.5 Polymer [wt. %] Redispersible copolymer.sup.6) 1.0 1.5 3.0 Additives [wt. %] Plasticizer.sup.7) 0.06 0.08 0.07 Processing additives.sup.8) 2.14 3.12 3.93 .sup.1)Alicem, available from Heidelberg Cement, Germany .sup.2)Fillite 500, alumina-silicate spheres with particle size 5-500 m, available from Omya, UK .sup.3)Expanded clay, particle size 0-2 mm .sup.4)Poraver, particle size 0.5-1.0 mm, Dennert Poraver GmbH, Germany .sup.5)Vermiculite superfine .sup.6)Highly flexible dispersion powder based on vinylacetate-ethylene (Tg = 7 C.) .sup.7)Sika Viscocrete 125, polycarboxylate ether, Sika Germany .sup.8)Defoamer, rheology modifiers, thixotropic agents

(4) Mortar compositions M1-M3 have been mixed with water (for proportions see table 2) in order to obtain processable compositions. Flow table spread values were assessed similar to standard EN 12350-5:2009. Compressive strengths have been determined similar to standards EN 12390-1 to 12390-4:2000.

(5) TABLE-US-00002 TABLE 2 Mortar properties Property M1 M2 M3 Water content.sup.1) [wt. %] 22 24 24 Flow table spread [mm] After 0 minutes 195 208 182 After 30 minutes 180 186 175 Compressive strength [MPa] After 24 hours 33.5 29.0 29.5 After 7 days 34.5 33.9 33.3 After 28 days 39.5 38.5 37.6 .sup.1)weight ratio of water to total weight of dry mortar composition

(6) Thus, the mortar compositions show a flow behavior which makes processing easy and allows for easy application of the mortars.

(7) Tests with the mortar compositions similar to EN 12004-1/2:2017 revealed that properties according to criteria C1E S2 and C2E S2 are achievable.

(8) 2. Adhesive Compositions

(9) Table 3 shows seven 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.

(10) TABLE-US-00003 TABLE 3 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 Slag 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 dispersion powder based on vinylacetate-ethylene-acrylicacid ester terpolymer .sup.6)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 NT10, phyllosilicates, Byk-Chemie GmbH, Germany .sup.10)Defoamer, rheology modifiers, thixotropic agents

(11) 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.

(12) 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.

(13) 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).

(14) 3. Flooring Applications

(15) 3.1 Floor Structures

(16) 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 mat of stone wool (mineral wool) with a thickness of 12 mm. On top if this first layer of stone wool a layer of mortar composition M1 (as described above in table 1) with a thickness of 20 mm was applied (=second layer). Subsequently, this second layer was covered with a third layer consisting of adhesive composition C3 (as described above in table 3) with a thickness of 4 mm. On top of the second layer, ceramic tiles were placed.

(17) A second floor structure was prepared similar to the first floor structure. However, in this case, the third layer (adhesive) as well as the tiles has been omitted. Thus, the second floor structure consisted only of the substrate, the first layer (stone wool) and the second layer (mortar composition).

(18) 3.2 Tests with First Floor Structure

(19) In order to test a floor's performance, dynamic load capacity tests according to standard ASTM C627-18 (test method for evaluating ceramic floor tile installation systems with a Robinson-type floor tester) are widely accepted to test installed tile floors.

(20) Thereby, a three-wheel cart is rotated about its center on the top of a sample section of a tile floor. Each wheel can be loaded with a predefined weight. The test comprises 14 different cycles whereby for each cycle, a type of wheel to be used (soft rubber, hard rubber, or steel), the weight to be loaded on each wheel, and the total number of revolutions to be executed is defined. From cycle 1 to cycle 14, the conditions get more and more demanding. Samples completing cycle 12 without failure are considered suitable for heavy commercial applications, such as e.g. in shopping malls, commercial kitchens, work areas, automotive service areas, and exterior decks. A floor passing cycle 14 without failure can withstand maximum dynamic loads to be expected with high-impact applications.

(21) Dynamic load capacity tests according to the standard ASTM C627-18 with the first floor structure have shown that the floor structure can pass cycle 14 with some cracks in the tiles. However, the floor structure can be considered suitable for heavy commercial applications.

(22) Tests according to ISO 10140-3:2010 and ISO 717-2 showed very high impact noise reductions Lw of 28 dB for the first floor structure.

(23) Thus, the first floor structure features in combination a very high impact noise reduction and at the same time a very high mechanical stability.

(24) 3.3 Test with Second Floor Structure

(25) The second floor structure (without tiles) was tested in a static load capacity test according to standard EN 1991:2010. The test was passed with a load of 600 kg. Thus, the floor structure shows a high mechanical stability.

(26) 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.