U.S. patent number 3,839,059 [Application Number 05/322,271] was granted by the patent office on 1974-10-01 for sprayable gypsum plaster composition.
This patent grant is currently assigned to W. R. Grace & Co.. Invention is credited to Ralph J. Bragg, Raymond E. Rothfelder.
United States Patent |
3,839,059 |
Rothfelder , et al. |
* October 1, 1974 |
SPRAYABLE GYPSUM PLASTER COMPOSITION
Abstract
Fire-retardant coatings for structural metal members are
obtained by spraying onto the metal settable plaster compositions
which are air-containing pumpable aqueous slurries of compositions
consisting essentially of, on a dry weight basis, from 52 to 62
percent calcined gypsum, from 2.5 to 18 percent high wet bulking
cellulosic fiber, sufficient foaming agent to achieve good
workability and satisfactory pumping characteristics, and enough
lightweight aggregate to complete the formula.
Inventors: |
Rothfelder; Raymond E. (Irvine,
CA), Bragg; Ralph J. (Arlington, MA) |
Assignee: |
W. R. Grace & Co.
(Cambridge, MA)
|
[*] Notice: |
The portion of the term of this patent
subsequent to March 6, 1990 has been disclaimed. |
Family
ID: |
27184430 |
Appl.
No.: |
05/322,271 |
Filed: |
January 9, 1973 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
122703 |
Mar 10, 1971 |
3719513 |
|
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Current U.S.
Class: |
106/644; 106/674;
106/675 |
Current CPC
Class: |
C04B
28/14 (20130101); C04B 20/0052 (20130101); C04B
18/241 (20130101); Y02W 30/97 (20150501); Y02W
30/91 (20150501) |
Current International
Class: |
C04B
18/04 (20060101); C04B 18/24 (20060101); C04B
20/00 (20060101); C04B 28/00 (20060101); C04B
28/14 (20060101); C04b 011/00 () |
Field of
Search: |
;106/109,111-115 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Gantz; Delbert E.
Assistant Examiner: Sheehan; John P.
Attorney, Agent or Firm: Baker; William L. Parker; C.
Edward
Parent Case Text
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of application, Ser. No.
122,703, filed Mar. 10, 1971 now U.S. Pat. No. 3,719,513.
Claims
1. A gypsum plaster composition, capable of yielding a settable,
sprayable slurry on addition of water, which consists essentially
of on a dry weight basis, calcined gypsum, about 52 to 62 percent,
high wet bulking cellulosic fiber, about 2.5 to about 18 percent,
an air-entraining agent, about 0.2 percent, and sufficient
lightweight aggregate to complete the formula, said cellulosic
fiber having sufficient wet bulking capacity that when incorporated
in the said composition, admixed with water, pumped and sprayed,
yields at least about 24 board feet of product per 50 pounds of
2. The composition of claim 1 wherein the cellulosic fiber
constitutes from
3. The composition of claim 2 wherein the cellulosic fiber is
provided by a
4. The composition of claim 2 wherein the cellulosic fiber is
provided by a
5. The composition of claim 1 wherein the lightweight aggregate is
an expanded vermiculite having a bulk density within the range of
about 4.5
6. The composition of claim 1 wherein the wet bulking capacity of
said cellulosic fiber is sufficient to yield at least about 28 to
32 board feet
7. A sprayable, settable plaster slurry consisting of the plaster
composition of claim 1 suspended in water at a level of about 9 to
about
8. A fire-retardant set gypsum plaster composition metal structural
assembly consisting of structural metal members coated with the
composition of claim 6.
Description
THE PRIOR ART
In the course of erecting steel structures, a thick coating of
inorganic material is commonly applied to the metallic structural
elements to achieve a number of objectives including fire
retardance, improved appearance and sound deadening. While several
types of formulations have been applied for these purposes over the
years by means of a variety of techniques, the most successful
system so far consists in spraying onto the steel surfaces settable
aqueous mixes composed essentially of calcined gypsum, a
lightweight inorganic material such as exfoliated vermiculite, an
inorganic fibrous substance, preferably asbestos, and a foaming
agent. A composition of this type is described by Petersen in U.S.
Pat. No. 3,369,929, along with the most desirable application
technique, i.e., pumping the aqueous mix and spraying it directly
onto the steel in one layer.
In order to be suitable for such use, coating mixes, both in the
wet and dry state, must possess a number of crucial properties.
They must be able to hold the large quantity of water that renders
them capable of being pumped easily and to great heights. Yet they
must retain a consistency sufficient to prevent segregation or
settling of ingredients and permit adequate "yield" or coverage of
steel surface at a given thickness. The coating mixes, furthermore,
must obviously adhere to steel surfaces, both in the slurried state
and in the dry state. Also, the mix must set without the undue
expansion or shrinkage which could only result in the formation of
cracks that would seriously deter from the insulative value of the
dry coating.
As intimated earlier, this complex balance of properties has
substantially been achieved heretofore by gypsum-vermiculite mixes
containing asbestos fiber. However, health considerations have
recently caused the banning of asbestos-containing compositions,
thus leaving the industry without an acceptable substitute.
Elimination of the asbestos from the type of composition just
discussed results in changes in properties that are sufficiently
extensive to render them unsuitable for the application
contemplated.
SUMMARY OF THE INVENTION
It has now been discovered settable, sprayable plaster composition
yielding satisfactory fire resistance can be made by adding water
to a mixture consisting essentially of calcined gypsum, a
lightweight aggregate material such as exfoliated vermiculite,
cellulosic fiber of high wet bulking capacity, and sufficient
foaming agent to provide good workability and pumping
characteristics. The composition of the invention contains, on a
dry basis, about 52 percent to about 62 percent calcined gypsum,
about 2.5 percent to about 18 percent cellulose fiber, about 0.2
foaming or air-entraining agent, and enough lightweight aggregate
to complete the formula.
A cellulosic fiber of high wet bulking capacity is defined, for the
purpose of this invention, as a fibrous cellulosic material which
when incorporated in the composition of the invention, admixed with
water, pumped and sprayed, yields at least about 24, preferably 28
to 32 board feet or product per 50 pounds of dry composition.
DETAILED DESCRIPTION
The following examples are provided to illustrate the compositions
of the invention as well as their excellent properties.
EXAMPLE 1
A settable gypsum plaster composition is prepared by dry mixing the
following ingredients:
% By Weight ______________________________________ Calcined gypsum
288.3 lbs. 58% No. 3 vermiculite 188.3 lbs. 38% Cellulose fiber
19.9 lbs. 4% 496.5 lbs. 100%
______________________________________
To this mixture is added a small quantity of air-entraining agent.
In this instance, this amounts to one pound of technical sodium
lauryl sulfate.
The vermiculite used in this preparation is a standard grade of
expanded material having density of 5.25 pcf. The cellulose fiber
is a purified unbleached softwood cellulose consisting of over 99.5
percent cellulose and having a particle size distribution such that
approximately 33 percent of the material is retained on a No. 60
Tyler screen with about 33 percent more retained on a No. 150
screen.
The dry mixture just described can be stored until desired. At the
point of use, it is thoroughly admixed with water and is
sufficiently agitated, or otherwise aerated, to provide a slurry of
the proper consistency which can then be pumped through
spray-application apparatus for direct spraying onto metal
surfaces.
FIRE-RESISTANCE OF PLASTER COMPOSITIONS
Fire-resistance classifications, or so-called fire ratings, based
on "Conditions of Acceptance" for floor and roof in the standard
for Fire Tests of Building Constructions and Materials,
Underwriters' Laboratories 263 (ASTM E119, NFPA 251) have been
obtained for steel structures coated with the plaster of this
invention, for example, for coatings on structural steel columns of
size W10.times.49 and larger:
Thickness of Coating Duration of Protection
______________________________________ 21/2 inches 4 hrs. 17/8
inches 3 hrs. 11/2 inches 2 hrs.
______________________________________
This degree of fire resistance which is comparable to that of
asbestos-containing plaster, is rather remarkable on considering
that the plasters of this invention are formulated with combustible
cellulose fibers, a development which contrasts with the trend of
the art calling for employment of inorganic fibrous substances.
EXAMPLE 2
A conventional asbestos-containing sprayable plaster composition
was prepared essentially as in Example 1, mixed with water,
properly aerated, sprayed on steel and allowed to dry and set. The
dry mix ingredients of this composition were as follows:
lbs. % by Weight ______________________________________ Gypsum 433
58.55% Vermiculite No. 3 212.5 28.73% Asbestos 93.0 12.58% Sodium
Laurylsulfate 1.0 0.14% 739.5 100.00%
______________________________________
A number of properties of coatings obtained from the
asbestos-containing composition of this example were compared to
those of cellulose fiber formulations. It was noted that the latter
product generally performs better than asbestos formulation.
Specifically, it was determined that on an equal density basis, set
cellulose fiber plaster has a greater surface hardness, a higher
modulus of elasticity, a lesser thermal conductivity and a smaller
volume change during setting than comparable conventional asbestos
fiber plaster.
These differences in properties and behavior at normal plaster
densities are illustrated by the accompanying drawings in which
FIG. 1 shows the modulus of elasticity,
FIG. 2 shows differences in surface hardness at normal
densities,
FIG. 3, the thermal conductivity or "K factor," and
FIG. 4, the movement of the plaster mass as it sets.
The modulus of elasticity was determined according to ASTM method
C-293. As shown in FIG. 1, the modulus (E) rises from about 5,000
to 11,000 psi for cellulose fiber-containing plaster over a density
range of 19 to 23 pcf, a level roughly twice that of asbestos fiber
plaster over the same density range. Inasmuch as a high modulus
ultimately contributes to some extent to hardness of the material,
the unexpected increase in modulus is beneficial for an application
such as that to which the compositions of the invention are
destined. Hardness determinations carried out on the same materials
support this improved picture at the densities tested by revealing
essentially a two-fold increase in penetration resistance (FIG. 2).
These penetration resistance values were obtained by means of a
Soiltest Penetrometer Model C421, using a 0.05 square inch needle
and a penetration depth of 0.25 inch. Given the mechanical abuse
that a lightweight plaster must undergo in the course of erecting
and finishing a building, the added surface hardness of the plaster
of the invention is indeed welcome. Another greatly appreciated
result of increased surface hardness, both at the construction
stage and during the entire life of the structure, is the
non-dusting characteristic of the new materials now disclosed.
The trade acceptability of the lightweight organic-fiber-containing
plasters of this invention for fire resistance applications has
already been disclosed. Among the properties which contribute to
this fine resistance, a crucial one is certainly thermal
conductivity or, as measured in the trade, the "K factor." This
value is the conventional coefficient of thermal conductivity
expressed in btu-inch/hour square foot .degree.F. A determination
of this K factor by the ASTM method C177-63 demonstrated that, at
equal density, cellulose-containing plaster possesses a lower
conductivity than asbestos plasters (FIG. 3). One can only
speculate on the reasons for this improved value.
FIG. 4 illustrates another important characteristic of lightweight
plasters, the volume stability on drying and setting. It is obvious
that when volume changes past a certain magnitude, varying degrees
of undesirable results such as cracking peeling, bulging, etc.,
will occur, with attendant decrease in the utility of the material.
On determination by optical measurement of the volume changes in
drying and setting standard masses (900mm .times. 75mm .times. 20mm
bars) of various compositions over a period of 9 days, i.e., a
period long enough for all movement to cease, it was found that
cellulose-containing plasters are more volume stable than their
asbestos counterpart, both in overall magnitude of volume change in
any direction and in net volume change.
EXAMPLE 3
Kraft process fiber, 20 parts, is suspended in water, 1,050 parts,
to form a slurry. To this is then added with mixing No. 4 expanded
vermiculite, 189 parts, CaSO4, 1/2 H.sub.2 O, 288 parts, and 45
percent sodium lauryl sulfate, 1.5 parts.
The Kraft process fiber used here is a cook sulfate originating
from a blend of western red cedar, hemlock and spruce. The fibers
average 2.70 mm in length and a screen analysis reads as
follows:
+ 14 mesh 59% weight + 28 24 + 48 7 +100 5 -100 5
The resulting plaster has a setting time of about 3 hours and 20
minutes. It showed an average wet density of 73.12 pcf and an
average dry density of about 14.6 pcf. The material is comparable
to the plaster of Example 1 in all respects.
The compositions of the invention, as mentioned earlier, contain
gypsum as well as a lighweight aggregate, an organic fibrous
material and a foaming agent.
As a lightweight aggregate, there may be used instead of the
expanded vermiculite of Example 1, any lightweight inorganic
material having a density within the range of about 4.5 to about 8
pcf. Perlite, clay and slag, in the expanded state, as well as
diatomaceous earth are examples of useful materials. Vermiculite,
however, is preferred not only because the intermediate slurries
containing it pump best, but also because of the greater plaster
thickness that can be applied in one pass when it is the aggregate
selected.
The foaming agents or air-entraining agents, that can be used in
the formulation of the invention are well known to the art and thus
can be disposed of without too much comment. Suffice it to say that
such materials as sulfated monoglycerides, sodium alkyl
arylsulfonates of various manufacture, sodium lauryl sulfate and
the like are used in quantities sufficient to cause the aqueous
slurries to achieve the consistency needed for pumping and
spraying. Obviously, dry foaming agents can be incorporated into
the dry gypsum-aggregate-fiber mixes before dilution with water,
while both dry and liquid agents can be used once the slurry is
made. In any event, as little as about 0.5 percent of foaming
agent, dry basis, may suffice for a given formulation.
The high wet bulking cellulosic fibrous component of the plaster of
the invention constituting, as seen earlier, from about 2.5 percent
to 18 percent of the mix on a dry basis and preferably about 3 to 8
percent, consists of short or chopped organic fibers of natural or
synthetic origin which when incorporated in the composition of the
invention, admixed with water, pumped and sprayed, yields at least
24 board feet of product per 50 pounds of dry composition. Board
foot (a volume equivalent to 1".times.12".times.12") yield of
product per pound of dry composition of the invention may be
determined by intermixing a known quantity of water (in pounds),
then after pumping and spraying in the conventional manner,
obtaining unit weight of the sprayed product and mathematically
calculating yield. Thus, ##SPC1##
Board foot yield per 50 pounds of starting dry composition would
thus be determined by: ##SPC2##
Nozzle density can be readily calculated by one skilled in this
art. For instance, the pumped product as discharged from the nozzle
is collected in a vessel of known volume (for convenience, 1 cubic
foot). The net weight of collected product is then measured. From
this the weight in pounds, per cubic foot of the collected product
is easily determined. Usable materials in this class include
cellulose fibers generally such as wood fiber, sisal, hemp, cotton,
jute, ramie, rayon and the like which either possess the required
bulking ability naturally or have acquired it by appropriate
physical and chemical modification, for instance, by
delignification. A preferred material of this type is the purified
softwood fibers used in Example 1.
In certain instances, it may be desirable to incorporate a small
proportion, say up to about 8 percent, preferably about 0.25 to 1.5
percent of inorganic fibers such as glass, Wollastonite, etc.,
fibers, in the composition of the invention. The following is one
example of such a composition:
Example 4 ______________________________________ % by Weight
______________________________________ Calcined gypsum 57.5%
Vermiculite 38.0 Cellulose fiber 4.0 Glass fiber 0.5
______________________________________
To this is added the desired amount of air-entraining agent to
complete the formula.
Having thus described the invention, especially in terms of
application to steel surfaces, is should be noted that the fire
resistant compositions disclosed will also adhere quite well to
other common materials, such as wood, cement, brick and the like.
It will further be apparent to the man skilled in the art that the
formulations described may be altered to some degree, for example,
by the addition thereto of further unspecified ingredients, without
departing from the scope of the invention as defined by the
following claims.
* * * * *