FOAMABLE COMPOSITION

Abstract: A foamable composition which when mixed with water will quickly provide a low density high strength product comprises a particulate pozzolan eg. a fly ash, a rapid setting agent eg. aluminium sulphate and a source of an eaxpansion gas eg. a carbonate to provide carbon dioxide. A strengthening agent eg. calcium sulphate and a lightweight filter eg. perlite, may be present.

Description: The invention relates to the placing of a foamable composition, and in particular a rapid setting foamable grout, by spraying on to a substrate. It is known from GB-A-402101 to form a porous plaster from water and a composition comprising particulate anhydrite, an accelerator such as a sulphate, a gas producing ingredient, e.g. a carbonate to produce carbon dioxide gas, and a small amount of Portland cement. The composition is allowed to set at a slow rate. The cement is present to reinforce the cellular structure, i.e. to prevent premature collapse. Clinker may also be present. The porosity may be varied by variation in the gas producing system. It is known from US-A-2606127 to form a composition for making lightweight building insulating articles, the composition comprising acidulous anhydrous calcium sulphate residue and a siliceous material, e.g. fly ash, smelter slags, cinders, hydrated combustion residues. The composition expands by about 25 to 30% and the density is about 0.9 to 1.2. It is known from US-A-1906138 to combine a binder,'e.g. Plaster of Paris, an aggregate and a gas evolving mixture (e.g. calcium carbonate and aluminium sulphate) to form a sound absorbing wall surface. This invention is based on the realisation that if a slurry is made of a defined particulate material, a gas producing ingredient and water, and this is combined with a solution of a rapid setting agent and the combined slurry and the solution are applied as a spray to a surface, the formed low density foam composition and can be applied to vertical surfaces quickly. Accordingly in one aspect the invention provides a method of placing a rapidly-setting foamable composition on a substrate, the method comprising mixing together a filler, a gas producing ingredient, a rapid setting agent which when dissolved in water will form an acidic solution, and water characterised in that the filler is a pozzolan which is formed into a slurry with the gas producing ingredient and water, the rapid setting agent is dissolved in water to form an acidic solution, and in that the slurry and the solution are separately pumped through a mixing device and in that the formed mixture is sprayed on to the substrate. The pozzolan is preferably a fly ash, preferably pulverised fly ash having a particulate size less than about 40 micron. Slags such as blast furnace slag may be used, especially if measures are taken to reduce the evolution of hydrogen sulphide therefrom. Cements are not suitable as the only filler because of their alkalinity but a proportion of a cement can be tolerated so long as the combined composition are sufficiently acidic for sufficient time to cause or allow the evolution of the expansion gas. Before the composition is allowed to set, the gas evolved causes a foaming, which increases the total volume significantly. Before the foam can collapse, the rapid setting agent causes the composition to set, as a result of which the foam is quickly stabilised. The use of additives such as foam stabilisers can accordingly be reduced or avoided. The rapid setting agent is most preferably aluminium sulphate. Preferably this agent makes up from about 1 to about 15% by weight of the composition. The expansion gas is preferably carbon dioxide and the source thereof may be calcium carbonate, sodium carbonate, magnesium carbonate or the like. Bicarbonates may also be used. The source may make up from about 1% to about 10% by weight of the composition, (i.e. the dry powder before water is added). It is an advantageous feature of the invention that the source of the expansion gas is selected so that the gas expansion does not take place until required, for example, until a combined composition is placed. This degree of control can be achieved by providing the source of expansion gas with a protective coating which is released or removed when the gas is required. As preferred examples the coating may be a starch or stearate coating applied to the source of expansion gas, which coating is dissolved off under slightly acidic conditions, e.g. a pH of about 4 to about 6. A strengthening agent may be present to strengthen the foamed composition. The strengthening agent is one which reacts at high speed to help stabilise the foam and for this purpose most preferably is calcium sulphate hemi hydrate. The composition may include a low density particulate filler which has a density not exceeding 0.5gm/cm³. In addition the filler must be one which will not detract from the high strength. This can be achieved either by selecting filler which also has a relatively high strength or which will be reactive in this context and thus contribute to the high strength. Fillers which are of low density and non-reactive include perlite, vermiculites and foamed polystyrene; fillers which are of low density and reactive include hollow pulverised fly ash spheres; expanded blast furnace slags; hollow glass spheres; foamed glass beads. The content of this filler may make up from about 5 to about 50% by weight of the dry composition. The particle size of the particulate filler component will be selected to be compatible with the other ingredients. Typically, the particles will have a mean particle diameter of below 5 mm, and above 0.1 mm. The amount of filler will usually be less than proportion of the pozzolan. The slurry is pumped from one source to the desired location. A solution of the fast setting agent is pumped from a second source to the desired location. Before placement the two liquids are mixed, e.g. by use of a mixing nozzle of the type used in spray concrete, and the combined liquids are placed as required. As a result, a foam is quickly formed on the sprayed substrate, and the foam is set before it can collapse. This is especially advantageous when spraying vertical walls and permits the speedy removal of shuttering. A composition of the invention may be used for a variety of industrial purposes. For example, in mining, the composition may be used to form a set body in void filling, archway filling, roof support and mine wall insulation. In construction the composition may be used as a set body in cavity insulation, thermal insulation, cavity filling, fire control or protection and lightweight panels. The body may be shaped as boards, blocks, etc. The invention is illustrated by the following examples, in which unless otherwise stated parts are by weight. Example I 100 gms of powder comprising: pulverised fly ash 80 CaSO₄. 1/2 H₂o 17 CaCO₃ 3 was added to 20 ml of a solution of 500 gms Al₂ (S0₄)₃. 14 H₂O dissolved in 1000 gm water. Foaming occurred after a few seconds and the foamed mass became rigid after about 70 seconds. The grout had the following properties: Example II Different proportions of aluminium sulphate were added to compositions comprising pulverised fly ash and water, and the rate of setting was noted. The following results were obtained: % aluminium sulphate initial set (min) final set (min) 0.0 24 hours + - 0.5 220 300 1.0 190 240 1.5 140 200 2.0 18 55 2.5 6 35 5.0 4 9 Example III 100 gms of powder comprising: pulverised fuel ash 60 ordinary Portland Cement 30 CaCO₃ 10 was mixed with 30 ml of a solution of 500 gms Al₂(SO₄)₃. 14 H₂O dissolved in 1000 gm water. Foaming occurred almost immediately and the foamed mass set rapidly to give a foamed grout having the following properties: This example shows that even when a proportion of cement is present, there is sufficient acidity for the CO₂ to be released to foam the fuel ash. Example IV 100 gms of powder comprising: anhydrite or Plaster of Paris 90 CaCO₃ 10 was mixed with 40 ml of a solution of 500 gms Al₂(SO₄)₃ 14 H₂O dissolved in 1000 ml of water. Foaming occurred immediately followed by very rapid setting of the foamed mass which had the following properties:

Claims: A method of placing a rapidly-setting foamable composition on a substrate, the method comprising mixing together a filler, a gas producing ingredient, a rapid setting agent which when dissolved in water will form an acidic solution, and water characterised in that the filler is a pozzolan which is formed into a slurry with the gas producing ingredient and water, the rapid setting agent is dissolved in water to form an acidic solution, and in that the slurry and the solution are separately pumped through a mixing device and in that the formed mixture is sprayed on to the substrate. A method according to Claim 1 characterised in that calcium sulphate hemi hydrate is included in the slurry to stabilise the foam sprayed on to the substrate. A method according to Claim 1 and 2 characterised in that a low-density particulate filler which will contribute to the strength of the set composition is present in a concentration of from 5% to 50% by weight of the composition. A method according to any preceding Claim characterised in that the gas producing ingredient is covered by a protective coating e.g. a starch or stearate coating, which is dissolved off when the slurry is mixed with the solution. A method according to any preceding Claim characterised in that the pozzolan is pulverised fly ash or blast furnace slag.

Inventors: SMART, RODERICK MACDONALD
Applicants: FOSROC INTERNATIONAL LIMITED
Application year: 1987
Main classification: C04B28
IPC codes: C04B28