Riverstone reactive methacrylate resins as bindging agent for mineral fillers for producing elements and pre-cast segments.

Transcription

1 Plasti-Chemie International GmbH Klopstockstraße 19 D Plauen Produktion und Vertrieb von Plastifloor - Bodenbeschichtung Plastistone - Kiesbodenbelägen Plasticoate - Dachbeschichtungen Plastherm - Fassadenbeschichtung Riverstone - Bodenplatten Klopstockstraße 19 D Plauen Tel.: +49 (0) 37 41/ Fax: +49 (0) 37 41/ info@plasti-chemie.de Internet: Riverstone reactive methacrylate resins as bindging agent for mineral fillers for producing elements and pre-cast segments. Content: 1. What is polymer concrete? 2. Riverstone - polymer concrete 3. Production 3.1 Production of filler mix 3.2 Production of Riverstone -mortar 3.3 Pouring and compacting 3.4 Curing (polymerization) 3.5 Demoulding

2 1. What is polymer concrete? Polymer concrete is a concrete with thermosetting resins as binding agent. Thermosetting resins usually epoxy - (EP-), methacrylate - (MA-), polyurethane - (PU-) or unsaturated polyester- (UP-) resins that are being cured (polymerized) at room temperature by adding polymerizing aids, substitute the cement-water-mix. Thus hardening takes place within a short period of time. Mechanical strength properties are also three times better than those of hydraulically bonded concrete. Curing (polymerization) of reactive resins is being effected by polyaddition for EPand UP-resins, and by radical polymerization for MA- and UP-resins. Polymer concrete will not supersede classic concrete but is a reasonable addition to the line-up of construction materials. Despite the price of minimum 0.20 /kg or /m3, up to maximum 1.10 /kg or /m3, there are several other properties, e.g. fir behaviour, that oppose to a general utilisation. Generally polymer concrete is being used for special construction elements where certain advantages of polymer concrete come to effect: a) High early strength b) High bending, compression and tensile strength c) high E-Module d) high abrasion resistance e) high impact resistance f) low water absorption g) good weather-resistance h) good chemicals-resistance i) decorative effects by surface structure j) decorative effects by colourants

3 2. Riverstone Concrete Riverstone - bonded polymer concrete consists of Riverstone - resin, hardener component 10 PA and fillers, where required with addition of colourants. Riverstone - resins are solvent-free, cold-curing methacrylat resins for producing polymer concrete. Due to C=C double bonds, these special blends of polymethyl methacrylate (PMMA) in methacrylic esters are able to cure (polymerization). These water-coloured liquid resins partially contain low quantities of paraffin waxes as evaporation protection. They also contain accelerator so that they polymerise after addition of hardener (initiator). Polymerization is an exothermic process thus heat is released. Polymerization process can no longer be interrupted once it has started. Aggregates are as for cement concrete but fire-dried, stone dust, sand, flint or split whereas their grain size needs to correspond to the wall thickness of the construction element. Rule of thumb: maximum possible grain = ¼ of most minimal wall thickness. The binding agent quantity lies between 200 and 400 kg/m³. Riverstone - resins are thus a substitution of cement and water. Riverstone - concrete serves for producing pre-cast segments, e.g. - Sheathing on and in buildings, attics, balustrades, cladding panels, plinth and wall sheathings, wall heating elements, - Window sills, table boards, radiator covers, - Floor tiles, self-supporting steps, heatable steps, platforms for weighbridges. - Barn floor tiles, feeding troughs, plant troughs, grave borders, tombstones, - Shower trays, wash-bowls, urinals, - Tennis practicing walls, ping pong and football tables - Swimming pool equipment, - kerbs, plinths, solar cells, machine frames - Natural stone bonding and reinforcement.

4 3. Production takes place as follows: 3.1 Production of filler mixes Depending on the required minimum wall thickness of the pre-cast segment, filler mixes so-called dryblends are being fabricated of single-grading fractions by using hardener 10 PA. The dryblend can be stored. The filler structure corresponds to a filler or Rothfuchs grading curve. 3.2 Production of Riverstone - mortar By adding Riverstone - resin to the dryblend, a wet blend forms in the compulsory mixer. Mixing time is 1-3 minutes. Afterwards the mix must be immediately processed. The earth-moist mortars contain according to the largest grain between 6 and 12 % Riverstone resin. 3.3 Filling and compacting The "wet blend" must be directly poured into the mould that is fixed onto the vibrating table and has been prepared with mould release agent. Vibration compacting takes place with frequencies of Hz, UpM. Only during the compacting process that takes 1 to 5 minutes, fixing elements may be inserted into the mortar. 3.4 Curing (polymerization) Curing of Riverstone - mortar inside the mould should be taking place in a tempered and vented room. This process can be accelerated by heat conduction. The mould may traverse a heated channel or canal. Besides, polymerization leads to a warming of 50 C to 60 C. 3.5 De-moulding Elements or pre-cast segment can usually be de-moulded after 45 to 60 minutes after surpassing the highest exotherm. Store the still warm elements plane until they have cooled down to room temperature.

5 4. Required investments: Filler stock 2-3 silos > /pc and preparation or 2-3 container > /pc screw conveyor > composition scale > Riverstone resin tank > processing or container > metering pump > compulsory mixer small, <50 L > compulsory mixer large, >100 L > vibrating table > Moulds of Wood holding time < 100 > 100 /m2 Plastic holding time < 1000 > 500 /m2 Aluminium holding time > 1000 > /m2 Steel holding time > 3000 > /m2 Ventilation and venting > Waste air purification >

6 Advantages of Riverstone concrete - Good storage stability of the resin - Easy processing, also on low temperatures - Low binding agent fraction - No post-curing - Low linear shrinkage - Subsequent repair possible - Fast disposability - High stability - Narrow wall thickness, low weight - Easy transport - Easy installation - Large fixing distance - Surface with various types of layout - High abrasion resistance - Very good light and weather resistance - Very good chemicals resistance - Odourless construction segments - Hardly flammable - Only little smoke gas formation in case of fire - No toxic gas formation in case of fire

7 Flow pattern for production of Riverstone concrete Areas with emissions: MMA emission (200g MMA/m²) Room ventilation and venting, explosion protection on utilisation of Gel-Coats Ventilation and venting Sound emission during compacting, level db A ~ 1-3 minutes per pulse Production process with normal drive > Production process with in special cases, on demand Legend 1.1 Riverstone resin consultation 1.2 Dosage of Riverstone resin 2.1 Riverstone hardener 10 PA stock 2.2 Filler stock, coarse grain 2.3 Filler stock, medium grain 2.4 Filler stock, flour grain 2.5 Colorants stock 2.6 Entrepot for dryblend, on demand 3.1 Weighing of fillers, Riverstone 10 PA colorants 4.1 Mixer for dryblend 4.2 Mixer for wet blend 5.1 Filling of moulds with Riverstone concrete 5.2 Compacting Riverstone - concrete by vibration > 100Hz, > 600 U.p.M. 6.1 Curing zone 7.1 De-moulding of Riverstone elements 7.2 Aftertreatment of elements, breaking edges, sawing 7.3 Packing, palletizing 8.1 Cleaning of moulds 8.2 Stock for moulds 9.1 Preparation of moulds, inserting mould release agents, apply Gel - Coat 9.2 Drying zone for release agents, curing of Gel - Coat Compending is possible at 4.1 with 4.2., 5.1 with 5.2, 7.2 with 7.3, 8.1 with 8.2, 9.1 with 9.2

8 Riverstone Concrete curing progression

9 Schematic structure for producing Riverstone -concrete: data concerning our products and devices as well as concerning our data and procedures are based on an extensive research work and an application technology experience. We obtain these results, with which we do not take over adhesion going beyond the respective single contract, in word and writing after best knowledge, reserve ourselves we however technical changes in the course of the product development. Beyond that our application technology service stands when desired for large consultation as well as for co-operation with the solution manufacturing and application technology problems for order. That does not relieve the user however to examine our data and recommendations before their use responsible for the own use. That applies - particularly for deliveries to foreign markets - also regarding the keeping of patent rights third as well as for applications and procedures, which are not expressly in writing indicated by us. The case of loss our adhesion is limited to indemnifications of same extent, as they plan our general terms of delivery and sales with lack of quality. Geschäftsführer: Gerichtsstand: USt-IdNr.: Bankverbindung: Volkmar Lull Hof/Saale DE Deutsche Bank PGK AG Chemnitz Registergericht: Chemnitz Steuernummer: BLZ HRB /116/03632 Kto.-Nr Wir akzeptieren auch ec-kartenzahlung.