Auto Clave Bricks
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Transcript of Auto Clave Bricks
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Autoclaved Building Material
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Definition:
products
1. Lime-silica bricks
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Definition:
Autoclaved buildinproducts
1. Calcium silicate
bricks (KS
Kalksandstein)
high compressive
strength
water absorption
freezing resitance
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Definition:
products
2. AAC - AeratedAutoclaved Concrete
(Porenbeton)
,blocks with high porevolume
low compressive strength
unique thermal properties
acoustic insulation
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
1866: Method to cure sand and lime under steampressure was patented by Van Derburg in England
Calcium Silicate
Bricks
1880: Further development and patent by Dr. WilhelmMichalis. He succeeded in producing a real artificialsandstone
1894: Start of industrial production in Germany afterintroduction of the first rotation presses (originallydevelopped for production of cattle feed)
History
1924 first technical standard published in Germany(DIN 106) for dimensions and size tolerances (2 mm),compressive strength (15 N/mm2),
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Production of
Calcium Silikate
Bricks1. Sand
2. Sand mixture
3. Lime (CaO)
4. Mixer
5. Reactor
6. 2nd mixer
7. Forming
8. Hacking
9. Autoclave
10. Steam production
11. Water supply
12. Steam
13. Storage
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
1879: foundation of "Yxhult StenhuggeriAktiebolag" in Kumla , Sweden, for mining of vast
Calcium Silicate
Brickslimestone deposit situated near the city of Yxhult
Drastic shortage of energy in the 1st world war inSweden government raised the standards forthermal insulation
1918: Swedish researchers start developing new
History 1
1923: Dr. Axel Ericsson, architect and researcher atStockholm University developed a procedure formanufacturing of AAC
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
1928: Karl August Carln, majority shareholder of"Yxhult Stenhuggeri Aktiebolag realized the potential
Calcium Silicate
Bricksof the new building material and acquired a license formanufacturing. He invested a large part of his assets toconvert the quarry to a production facility for AAC.
1929: Start of industrial production of "YxhultsAnghrdade Gasbetong (= hardened aerated concreteof the city of Yxhult
History 2
Abreviation of "Yxhults Anghrdade Gasbetong toYtong
1940: registration of the brand name Ytong theworlds first registered brand name for a building product
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
http://www.youtube.com/watch?v=x7C-QTZwMusProduction of
Aerated Autoclaved
Concrete
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Mineral reaction
Quartz + Lime + Waterform new mineralphases: CSH-phases
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Mineral reaction
Reaction artners:
Quartz + Lime + Waterform new mineralphases: CSH-phases
Conditions in the
170C 8 bar
200C 16 bar
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Sand + CaO + H2O
Mineral reaction in reactor
2 2
quartz into solution Ca(OH) 2 into solutionpH increases
semi-cr stalline CSH 11-Tobermorite
heating upin autoclave
C/S>1.5 C/S=0.83
semi-crystalline CSH incr. amount of withdecreasing C/S ratio 11-Tobermorite
autoclaving
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Mineral reaction
CSH- hases
Soluble in hot HCl: 11-Tobermorite
Soluble in cold HCl:
CSH-II
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Mineral reaction
-phases (Tobermorite)and etched quartzcrystal
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Mineral reaction
Ex eriment of Peters /Iberg (1978) showedthe relative mobility ofthe two reactionpartners
Silica moves towardsthe source of calcium
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Raw material
-Switzerland
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Comparative
study
Pure quartz-sand vssand from fluvioglacialdeposits
Amount of quartz isnot critical
impure sand can beused as raw material
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Pure raw material:Sand and CaO are combined from different sources
Al ternat ive raw
material
Do rocks and other material exist that have bothreaction partners already combined?
Research project at University of Berne 1977 1986investigating: -Molasse Basin muds from gravel washeries carbonatous mudstones microstructure of autoclaved products from thesesources
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Al ternat ive raw
material
Muds from gravelwasheries
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Al ternat ive raw
material
Muds from gravelwasheries
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Al ternat ive raw
material
Sandy mudstone
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Al ternat ive raw
material
Clay-rich mudstone
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Preliminary study
Exam le mudstones
Analysis ofmineralogicalcomposition of 41mudstone samples
Selection of 8representative samplesfor specimen fabrication
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Sampling of 40 80 kg directly from Molasse BasinSample treatment
Drying at 110 C in the laboratory oven
Jaw crusher size reduction and grinding to grain size
of < 1 mm in laboratory grinder
Pelletizing (with ideal diameter of 1 3 mm)
Analysis of mineralogical composition of untreatedsamples (XRD)
Activation of pelletized mudstone samples (after pre-study for ideal activation conditions)
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Analysis of mineralogical composition after activation
Grinding of activated pellets to grain size of
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Mineralogical
reaction
monitored w ith
autoclave XRD-
camera
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Manufacturing of
samples
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Density of blocksAnalysis of
physical
Compressive strength
Tensile strength
E-Modulus
Water absorption
properties
Shrinkage and swelling
Thermal conductivity
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Optical analysis
Cast sample
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Optical analysis
Thin section
Pressed sample
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
SEM analysis
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
SEM analysis
Polished sam les
320 x
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
SEM analysis
1250 x
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App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
SEM analysis
Polished sam les
5000 x
App lied Mineralogy an d Non -Metal lic Resou rces II Auto claved B ui ldi ng Materi al
Calcium silicate bricks can be manufactured fromConclusion
,and clay minerals
Especially sandy mudstones which have not been of
economical significance seem to be most suited
This increases the volume of potential raw material forbrick manufacturing
Pressed samples manufactured of sandy mudstonescompare well with industrial calcium silicate bricks
2 patents resulted from the research program foralternative raw material for autoclaved building material