Formulation for a low-carbon construction binder, method of production, and construction materials
The invention relates to a formulation of a low carbon construction binder including, in a dehydrated form, a raw clay matrix and a deflocculating agent. It also relates to a construction binder, a method of preparing this construction binder, as well as a construction material comprising the construction binder according to the invention.
1. A construction binder, including:
at least 30 wt % of a raw clay matrix, the raw clay matrix comprising rock materials, the rock materials consisting of one or more uncalcined rock materials;
a deflocculating agent;
at least 10 wt % of an activator composition, wherein the activator composition is an alkaline activator composition comprising a compound having a pKa greater than or equal to 10; and
at least 2 wt % of metal oxides.
2. The construction binder according to claim 1 , further comprising at least 40 wt % of the raw clay matrix.
3. The construction binder according to claim 1 , wherein the deflocculating agent is selected from the group consisting of:
a non-ionic surfactant;
an anionic agent;
a polyacrylate;
an amine; and
mixtures thereof.
4. The construction binder according to claim 1 , wherein the deflocculating agent accounts for at least 0.25 wt % of the construction binder.
5. The construction binder according to claim 1 , wherein the raw clay matrix, the deflocculating agent, and the activator composition form a two-component or multi-component system.
6. The construction binder according to claim 1 , comprising:
30 wt % to 80 wt % of the raw clay matrix;
0.25 wt % to 20 wt % of the deflocculating agent; and
10 wt % to 50 wt % of the activator composition.
7. The construction binder according to claim 1 , wherein the activator composition includes an organophosphorus compound.
8. The construction binder according to claim 1 , comprising at least 5 wt % of the metal oxides.
9. The construction binder according to claim 8 , wherein the metal oxides are selected from the group consisting of: iron oxides such as FeO, Fe 3 O 4 , FezO 3 , alumina Al 2 O 3 , manganese (II) oxide MnO, titanium (IV) oxide TiO 2 and mixtures thereof.
10. The construction binder according to claim 1 , further comprising:
a blast furnace slag composition, wherein the blast furnace slag composition accounts for at least 5 wt % of the construction binder.
11. The construction binder according to claim 1 , wherein the activator composition includes Portland cement.
12. The construction binder according to claim 1 , comprising:
40 wt % to 70 wt % of the raw clay matrix;
0.5 wt % to 6 wt % of the deflocculating agent;
10 wt % to 20 wt % of the activator composition; and
20 wt % to 45 wt % of blast furnace slags.
13. The construction binder according to claim 1 , comprising:
35 wt % to 65 wt % of the raw clay matrix;
0.5 wt % to 5 wt % of the deflocculating agent; and
31 wt % to 49 wt % of Portland CEM1 cement.
14. The construction binder according to claim 1 , comprising:
35 wt % to 65 wt % of the raw clay matrix;
0.5 wt % to 5 wt % of the deflocculating agent;
10 wt % to 30 wt % of blast furnace slags; and
15 wt % to 35 wt % of Portland CEM1 cement.
15. The construction binder according to claim 1 , comprising:
45 wt % to 70 wt % of the raw clay matrix;
0.5 wt % to 6 wt % of the deflocculating agent;
10 wt % to 35 wt % of the activator composition; and
15 wt % to 30 wt % of metakaolin.
16. The construction binder according to claim 1 , comprising:
45 wt % to 70 wt % of the raw clay matrix;
0.5 wt % to 5 wt % of the deflocculating agent;
10 wt % to 25 wt % of the activator composition;
5 wt % to 20 wt % of blast furnace slags; and
15 wt % to 30 wt % of metakaolin.
17. The construction binder according to claim 1 , wherein the deflocculating agent is selected from the group consisting of:
a polyoxyethylene ether;
an anionic agent selected from: alkyl aryl sulphonates, amino alcohols, carbonates, silicates, fatty acids, humates, carboxylic acids, lignosulphonates, polyacrylates, phosphates or polyphosphates, sodium tripolyphosphate, sodium orthophosphate, carboxymethylcelluloses, and mixtures thereof;
a polyacrylate selected from sodium polyacrylate or ammonium polyacrylate;
an amine selected from: 2-amino-2-methyl-1-propanol; mono-, di- or triethanolamine; isopropanolamines; and N-alkylated ethanolamines; and
mixtures thereof.
18. The construction binder according to claim 1 , wherein the activator composition includes an organophosphorus compound including sodium tripolyphosphate, wherein the organophosphorus compound accounts for at least 2 wt % of the construction binder.
19. A method of preparing the construction binder according to claim 1 , comprising:
preparing a clay suspension including said raw clay matrix, said deflocculating agent, and water;
adding said activator composition to the clay suspension; and
mixing so as to obtain the construction binder.
20. The method according to claim 19 , further comprising:
adding aggregates, recycled or not, selected from fillers, powders, sand, grit, gravel, and/or fibers, and optionally pigments.
21. The method according to claim 19 , further comprising:
adding sand and water to form mortars, coatings or plasters.
22. A method of production, comprising:
admixing the construction binder according to claim 1 to produce one or more of: floor coverings, wall coverings, cladding panels, boarding elements, roof coverings of a tile type, extruded or molded construction modules, or various extruded shapes.
23. A method of production, comprising:
admixing the construction binder according to claim 1 to produce one or more of: composite materials, prefabricated blocks, prefabricated wall elements, or any other prefabricated construction element.
24. A method of producing concrete, comprising:
admixing the construction binder according to claim 1 to produce concrete having a minimum compressive strength on cylinders at day 28 as measured by the NF EN 206-1 standard greater than or equal to 20 MPa.