COMPOSITION AND METHOD OF MAKING FLEXIBLE FIBRE-POLYMER CONCRETE PANEL Russian patent published in 2024 - IPC C04B28/04 C04B16/00 C04B14/04 B28C5/40 

FIELD: construction.

SUBSTANCE: invention relates to construction materials, namely to a composition and a method of making a flexible fibre-polymer concrete panel, and can be used on facades, fences, in interiors. Flexible fibre-polymer concrete panel includes styrene-acrylic dispersion, white cement of “500 ДО” grade, carboxylate hyperplasticiser in powder Sika-225 ViscoCrete-226P, metakaolin, or microsilica, or their hybrid, fibre in the form of glass fibre, basalt fibre or polypropylene fibre with length of 6 mm, iron oxide pigment and microcalcite in the form of marble powder, quartz flour or ground limestone at a given ratio of components. Method of flexible fibre-polymer concrete panel manufacturing includes the following stages. At the first stage, a dry mixture is prepared, at which white cement of “500 ДО” grade is added to the mixer with revolutions of not more than 90 rpm, metakaolin, or microsilica, or a hybrid thereof, and a carboxylate hyperplasticiser in powder Sika-225 ViscoCrete-226P, stirring, activating the dry mixture for 5 minutes, iron oxide pigment is added and the obtained dry mixture is stirred for 5 minutes, microcalcite is added in the form of marble flour, quartz flour or ground limestone, then mixed for 5 minutes, obtained dry mixture is reinforced by adding glass fibre, basalt fibre or polypropylene fibre 6 mm long and mixed for 2 minutes. At the second stage, moulds are made from a polyurethane compound for pouring a concrete mixture, for which the mould is painted with a composition consisting of iron oxide pigment, titanium dioxide and water. At the third stage, the prepared dry mixture is poured into a horizontal mixer for production of concrete with highly filled compositions, water is added, and the styrene-acrylic dispersion is mixed in different parts: 70% immediately, until activation of the hyperplasticiser, mobility and saturation of the mixture with water, then remaining 30%, then brought to readiness for 3 minutes. At the fourth stage, prepared form of polyurethane compound is supplied via vibroline, in which basalt mesh is laid for reinforcement of fibre-polymer concrete panel in volume. At the fifth stage, the finished mixture is fed into a hopper with a batcher and the mould is filled through the basalt mesh, the mould is filled with the help of vibration and the mixture is compacted, after filling the mould, a substrate cut to the dimensions of the mould is applied, which consists of the following types of substrates, which have adhesion to the given concrete composition: foamed polystyrene, extruded polystyrene, cement-bonded particle board, “АБС” plastic, the mixture is vibrated to bond with substrate for 15 s, then the mould in the tray is sent to a heat chamber with temperature of 36 °C and air humidity of 100% for further strength gain, after 8–12 hours, the mould is supplied from the heat chamber to the demoulding table, where the mould is turned over and disassembled, the finished product in the vertical state is allowed to settle in a warm room for 1 day.

EFFECT: obtaining a high-density flexible fibre-polymer concrete panel having high compression, stretching and bending strength, water resistance, resistance to aggressive media, lightness and light resistance.

2 cl