A method of manufacturing a super-light polystyrene products

 

(57) Abstract:

The invention relates to the field of building materials, in particular, to a method of manufacturing a light polystyrene products with high thermal insulation and structural reliability and environmental safety. The purpose of the invention: increasing structural, operational reliability and environmental safety of polystyrene concrete and structures based on them. This objective is achieved in that the polystyrene concrete mixtures containing Portland cement, granules increased suspension of polystyrene, surface-active additive and water, use granular suspension polystyrene, pre-treated surface-active additive. Foaming of polystyrene is carried out in a mixture in a fixed volume form with simultaneous hydration of cement with live steam at a temperature of 95-105oC. it is Shown that the use of the proposed solution leads to an increase in physical and mechanical properties of finished products by 30-50 % and a significant reduction of residual styrene. 4 C.p. f-crystals, 4 PL.

The invention relates to the field of building materials, in particular, to the of capabilities in industrial and housing construction.

Known method of preparing lightweight concrete mixture, which consists in the processing of polystyrene granules composition based on polyvinyl acetate dispersion, followed by mixing the obtained granules with cement and mixing water in the following ratio, wt. polyvinyl acetate dispersion (dry substance) of 4.8 and 9.0; Portland 25,0-52,9; ash of thermal power plants 10,6-38,6 and water the rest [1]

The disadvantage of this method is relatively low mechanical strength of the finished products and their non-compliance with the essential requirements of environmental safety.

Also known a method of manufacturing sandwich panels, consisting in laying and compacting the concrete mix in the bottom layer, then stack insulation penopolistirolbeton mixture of the middle layer, containing, by weight. EPS 4,5-5,3; liquid glass (on dry basis) 1,2-4,0; Portland 66,0-70,0; resin wood saponified 0.08 to 0.12 and water the rest. After hardening of the middle layer within 5-15 min stack and seal the concrete mixture of the top layer [2] a disadvantage of the known technical solution is a great complexity and relatively high environmental hazard for MF is ment should include a method of manufacturing concrete products, comprising preparing a mixture of granules of foamed polystyrene, surface-active additives and cement zatvoreniem mixture with water, the laying of the mixture in the form, seal and heat treatment of the product [3]

The disadvantage of this method is the low mechanical strength of the finished products and their discrepancy with the essential requirements of environmental safety.

The purpose of the invention to reduce the complexity and increase constructive and operational reliability, particularly lung polystyrene products and increase their environmental safety by reducing emissions of free styrene in the environment.

This objective is achieved in that in the method of manufacturing a super-light polystyrene products, including the preparation of a mixture of polystyrene granules, surface-active additives and cement zatvoreniem mixture, packing it in a form and heat treatment, as the use of polystyrene granules granules suspension of polystyrene, and the zatvoreniem carried out after laying of the mixture in the form by filing it with a sharp pair with the formation of condensate in the mixture, the mixture contains components in the following ratio, wt.

Cement 75,5-82,5

Gr is the Rest

In this case, the zatvoreniem mixture of condensate and steam is carried out in a fixed volume form at a temperature of 95-105oC for 0.1 to 1.5 hour for simultaneous foaming process of self-packing of the mixture and cement hydration.

After mixing the mixture of the heat-treated product to produce at a fixed volume form at a temperature of 60-75oC for 12-16 hours. Thus, the laying of the mixture in the form produced in the amount of 0.25-0.37 volume form.

However, in the process of preparation of the mixture first by surface treatment of the granules suspension of polystyrene surface-active additive containing a mixture of organic dicarboxylic acids and resin wood saponified in the following ratio, wt.

A mixture of dicarboxylic acids 50-75

Resin wood saponified 25-50,

then mix with cement to obtain a homogeneous semi-dry mixture, the ratio of surface-active additive is 1: 0,038-0,097.

A method of manufacturing a super-light polistirolbetonnyh products is as follows.

The estimated amount of the original granules suspension newspring polystyrene is treated with a surface-active TES and 50-75 25-50 wt. respectively. Then mineralize cement followed by thorough stirring to the formation of the dry homogeneous mixture and placed in a perforated form in an amount to provide a given finite volume mass of finished products, the forms are then covered with a lid), designed to force the internal pressure of the concrete mix at the time of foaming polystyrene granules and self-packing, and exposed to live steam at a temperature of 95-105oC in a fixed volume form within 0.5-1.5 h followed by heat treatment at a temperature of 60-75oC for 12-16 hours Under temperature of steam is heating of the molding mixture and zatvoreniem condensate acute water vapor with simultaneous intensive swelling of the granules suspension of polystyrene, the self-sealing mix and cement hydration, which leads to the formation of a dense structure in the closed volume of the form when the stoichiometric ratio of the components in the system cement is water.

This goal can be achieved in the case when the surface-active additive in the preparation of molding sand is introduced into the aqueous solution and then is part of what densata sharp pair. This ensures the achievement of high physical and economic design and performance characteristics of finished products in compliance with the relevant standards of environmental safety. The latter is achieved by the introduction of molding a mixture of a special additive with high reactivity to the free styrene, which is released from polystyrene granules at the time of foaming.

The durability of the finished products was determined according to GOST 17117.10-81, bulk density according to GOST 17117.3-81, moisture in capillary suction within 5 days according to GOST 17117.5-81, and the presence of free residual styrene according to GOST 15820-82 "Polymers and copolymers of styrene. Gas chromatographic method for the determination of residual monomers and depolymerizes impurities".

In table. 1 shows the specific formulations of polystyrene concrete compositions according to the proposed method of manufacture of polystyrene products.

In table.2 shows the conditions of the method.

Specific examples of compounds known polystyrene concrete mixtures and conditions of manufacture of the products is given in table.3.

Physico-mechanical and Toxicological characteristics of finished products polisterola is blowing from the data are given in table.4, the proposed method of manufacturing a super-light polystyrene products leads to a significant increase in physical and mechanical properties, their structural and operational reliability. With an equal bulk density and thermal conductivity, tensile strength under compression and bending of finished products at the age of 28 days on the proposed method on 80-50 higher than for the known technical solution, and the amount of free styrene in the product does not exceed the norms of maximum permissible concentration (MPC=0.002 mg/l) and more than an order of magnitude smaller than the prototype (part 8). The implementation of the method outside the stated conditions (compositions 5,6) does not lead to the goal.

1. A method of manufacturing a super-light polystyrene products, including the preparation of a mixture of polystyrene granules, surface-active additives and cement zatvoreniem mixture, packing it in a form and heat treatment, characterized in that as the use of polystyrene granules granules suspension of polystyrene, and the zatvoreniem carried out after laying of the mixture in the form by filing it with a sharp pair with the formation of condensate in the mixture, the mixture contains components in the following ratio, wt.

Cement 75,5 82,5

Granules sue

2. The method according to p. 1, characterized in that the zatvoreniem mixture of condensate and steam is carried out in a fixed volume form when 95 105oC for 0.1 to 1.5 h for simultaneous foaming process granules suspension of polystyrene, self-packing of the mixture and cement hydration.

3. The method according to p. 2, characterized in that after mixing the mixture of the heat-treated product to produce at a fixed volume form at 60 - 75oC for 12 to 16 hours

4. The method according to PP.1 to 3, characterized in that the laying of the mixture in the form produced in 0,25 0,37 volume form.

5. The method according to PP.1 to 4, characterized in that in the process of preparation of the mixture first by surface treatment of the granules suspension of polystyrene surface-active additive containing a mixture of organic dicarboxylic acids and resin wood saponified, in the following ratio, wt.

A mixture of dicarboxylic acids 50 to 75

Resin wood saponified 25 50

then mix with cement to obtain a homogeneous semi-dry mixture, the ratio of the polystyrene surface-active additive is 1 0,038 0,097.

 

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