(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)

(19) World Intellectual Property

Organization I
International Bureau
(10) International Publication Number
(43) International Publication Date WO 2013/150148 Al
10 October 2013 (10.10.2013) P O PCT

(51) International Patent Classification: (81) Designated States (unless otherwise indicated, for every
C04B 28/02 (2006.01) C04B 38/10 (2006.01) kind of national protection available): AE, AG, AL, AM,
C04B 28/04 (2006.01) AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY,
BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM,
(21) International Application Number: DO, DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT,
PCT/EP2013/057238
HN, HR, HU, ID, IL, IN, IS, JP, KE, KG, KM, KN, KP,
(22) International Filing Date: KR, KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD,
5 April 2013 (05.04.2013) ME, MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI,
NO, NZ, OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU,
(25) Filing Language: English RW, SC, SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ,
(26) Publication Language: English TM, TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA,
ZM, ZW.
(30) Priority Data:
1253237 6 April 2012 (06.04.2012) FR (84) Designated States (unless otherwise indicated, for every
kind of regional protection available): ARIPO (BW, GH,
(71) Applicant: LAFARGE [FR/FR]; 6 1 rue des Belles GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, SZ, TZ,
Feuilles, F-75 1 16 Paris (FR). UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, TJ,
TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, DK,
(72) Inventors: BERNARDI, Sebastien; Lafarge Centre de
EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU, LV,
Recherche, 95 Rue du Montmurier, F-38291 Saint Quentin
MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM,
Fallavier (FR). JAVIERRE, Isabelle; Lafarge Centre de
TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW,
Recherche, 95 Rue du Montmurier, F-38291 Saint Quentin
ML, MR, NE, SN, TD, TG).
Fallavier (FR). DUCHAND, Sylvain; Lafarge Centre de
Recherche, 95 Rue du Montmurier, F-38291 Saint Quentin Declarations under Rule 4.17 :
Fallavier (FR). SABIO, Serge; Lafarge Centre de Recher
— of inventorship (Rule 4. 1 7(iv))
che, 95 Rue du Montmurier, F-38291 Saint Quentin Fal
lavier (FR). ROY, Cedric; Lafarge Centre de Recherche, Published:
95 Rue du Montmurier, F-38291 Saint Quentin Fallavier
— with international search report (Art. 21(3))
(FR).
(74) Agent: MERIGEAULT, Shona; Lafarge, 95 rue du Mont
murier, BP9, F-38291 Saint Quentin Fallavier Cedex (FR).

00

© (54) Title: INSULATING MINERAL FOAM

(57) Abstract: The present invention relates to a process for production of insulating mineral foams produced from a slurry of ce-
ment and an aqueous foam. The invention also relates to the mineral foam obtained by this process, its uses and elements of con -
struction produced with this mineral foam.
 INSULATING MINERAL FOAM

The present invention relates to a process for production of insulating mineral foams
with a base of cement, to the mineral foams thus obtained and to elements of construction
comprising these foams.
Generally, mineral foam is very advantageous for many applications due to its thermal
insulation properties. Mineral foam is a material in the form of foam. This material is generally
more lightweight than typical concrete due to its pores or empty spaces. It is also known as
cement foam. These pores or empty spaces are due to the presence of air in the mineral
foam and they may be in the form of bubbles. With 1 m3 of raw material it is possible to
produce approximately 5 m3 of a finished product, that is, a material wherein 20 % is material
and 80 % is air (this is valid for an element with a density of approximately 400 kg/m 3) .
When mineral foam is poured into an element of considerable height, the mineral foam
may slump due to a lack of stability in the mineral foam during the setting. These slump
problems of the foam may be due to coalescence phenomena, to Ostwald ripening
phenomena or to draining phenomena, the latter being greater, in particular due to the force
of weight.
The difficulty in the production of mineral foams is therefore to produce stable mineral
foam which reduces these slump problems. However, known processes are not capable of
providing sufficiently stable mineral foams.
In order to meet users requirements, it has become necessary to find a new means to

produce highly stable mineral foam, which is to say which keeps its stability whatever the
given height.
Therefore, the problem which the invention intends to solve is to find a process for
production of stable mineral foam, which does not slump, or only slightly, when the foam is
poured vertically.
The invention relates to a process for production of a mineral foam having a density of
100 to 600 kg/m 3, produced from a slurry of foamed cement as well as the mineral foam
obtained by this process.
According to another feature of the invention, the mineral foam according to the
invention may be used as construction material or insulating material. For example, the
mineral foam may be poured between two panels of gypsum boards, or between two brick
walls or between two load-bearing concrete walls.
The invention also relates to elements of construction comprising a mineral foam
according to the invention.
The present invention intends to provide a new process having one or more of the
following characteristics:
 - the process is universal, which is to say it makes it possible to produce a stable
mineral foam from any type of cement;
- the process is easy to implement;
- the process can be easily transported to any site or jobsite;
- the process makes it possible to implement a mineral foam in a continuous manner. It
is therefore possible to produce the mineral foam continuously and to pour this foam
without interruption.
The present invention also intends to provide new mineral foams which have one or
more of the following characteristics:
- the mineral foam according to the invention has excellent stability properties. In
particular, it is possible to obtain foam that does not slump or only very slightly when the
foam is poured vertically or from a considerable height. For example, the mineral foam
according to the invention does not slump or only very slightly when it is poured vertically
from a height greater than or equal to 2 metres;
- the mineral foam according to the invention has excellent thermal properties, and in
particular very low thermal conductivity. It is highly desirable to reduce thermal conductivity in
construction materials since this makes it possible to obtain savings of heating energy for
residence and office buildings. Furthermore, this decrease makes it possible to reduce
thermal bridges, in particular in the construction of buildings several stories high and
designed using indoor thermal insulation, in particular thermal bridges are reduced on the
intermediary floors.
Process:
The invention relates to a process for production of a mineral foam comprising the
following steps:
(i) separately prepare one or more slurries of cement and an aqueous foam for which
the D50 of the bubbles is less than or equal to 400 µη ;
(ii) homogenize this or these slurries of cement with the aqueous foam to obtain a slurry
of foamed cement;
(iii) cast the slurry of foamed cement and leave it to set.
The process for production of a mineral foam according to the invention may be used in
a discontinuous or continuous system.
In step (i), the slurry or slurries may be prepared using mixers typically used to produce

cement slurries. They may be a mixer for slurries, a mixer from a cement batching plant, a
mixer described in the European NF EN 196-1 Standard of April 2006 - Paragraph 4.4, or a
beater with a planetary movement.
The slurry or slurries may be prepared by introducing into the mixer the various powder
materials. The powders are mixed to obtain a homogenous mixture. Then, the water is
introduced into the mixer. Then, the mineral particles, the admixtures, for example the water-
reducer, the plasticizer, the superplasticizer or the retarder are introduced when they are
present in the formulation of the mineral foam. The obtained paste is mixed to obtain a
cement slurry or a mix of cement slurries.
Preferably, when calcium sulphate is present during the preparation of the cement
slurry, it is introduced before or after the addition of water. In particular, the calcium sulphate
is not introduced during the preparation of a slurry of calcium aluminate cement.
Preferably, the slurry or slurries are stirred using a deflocculating blade throughout the
duration of the process for production of the mineral foam according to the invention.
The cement slurries may be generated continuously in the process according to the
invention.
The water/total cement ratio of the slurry of foamed cement used to produce the
mineral foam according to the invention is preferably from 0.25 to 0.5, more preferably from
0.3 to 0.45. This water/total cement ratio may vary, for example due to the water demand of
the mineral particles when these are used. This water/total cement ratio is defined as being
the ratio by mass of the quantity of water (W) to the mass of all the cements (C).
In step (i), the aqueous foam may be produced by combining water and a foaming

agent, then introducing a gas. This gas is preferably air.

The introduction of air may be carried out by stirring, by bubbling or by injection under
pressure.
Preferably, the aqueous foam may be produced using a turbulent foamer (bed of glass
beads for example). This type of foamer makes it possible to introduce air under pressure
into an aqueous solution comprising a foaming agent.
The aqueous foam may be generated continuously in the process according to the
invention.
The generated aqueous foam has air bubbles with a D50 which is less than or equal to
400 µηι , preferably comprised from 100 to 400 µηι , more preferably comprised from 150 to
300 µηι .
Preferably, the generated aqueous foam has air bubbles with a D50 which is 250 µη .
The D50 of the bubbles is measured by back scattering. The apparatus used is the
Turbiscan ® Online provided by the Formulaction company. Measurements of the back
scattering make it possible to estimate a D50 for the bubbles of an aqueous foam, by
knowing beforehand the volume fraction of the bubbles and the refractive index of the
solution of foaming agent.
In step (ii), the slurry or slurries of cement may be homogenized with the aqueous foam

by any means to obtain a slurry of foamed cement.

 Preferably, step (ii) of the process according to the invention may comprise the
introduction of the slurry or slurries of cement and the aqueous foam into a static mixer to
obtain a slurry of foamed cement.
The suitable static mixers according to the invention preferably have elements in the
form of a propeller to ensure complete radial mixing and successive divisions of the flow for
each combination of liquids and gas. The suitable static mixers according to the invention
preferably have helical elements which transmit a radial speed to the fluid, which is directed
alternatively towards the side of the mixer, then towards its centre. The successive
combinations of elements directing the flow clockwise and counter clockwise provoke a
change of direction and a division of the flow. These two combined actions increase the
efficiency of the mixing. Preferably, the static mixer used in the process according to the
invention is a mixer operating by dividing the continuous flow of cement slurry and of
aqueous foam. The homogeneity of the mix is based on the number of divisions. According
to the process of the invention, 16 elements are preferably used to ensure good
homogeneity. The suitable static mixers according to the process of the invention are
preferably those commercialised under the brand name of Kenics®.
According to a more particular embodiment, the cement slurry is pumped at a precise
volume flow which is a function of the target composition of foamed cement slurry. Then, this
cement slurry is combined with the aqueous foam already circulating in the circuit of the
process. The slurry of foamed cement according to the invention is thus generated. This
slurry of foamed cement is cast and left to set.
According to variant 1, step (i) of the process for production according to the invention
may comprise the preparation of two slurries of cement, one of which is a slurry of calcium
aluminate cement.
According to this variant 1, the process for production according to the invention may
comprise the following steps:
- separately prepare a slurry of cement, a slurry of calcium aluminate cement and an
aqueous foam;
- combine the slurry of cement with the slurry of calcium aluminate cement to obtain a
third slurry of cement;
- homogenize this third slurry of cement with the aqueous foam to obtain a slurry of
foamed cement;
- cast the slurry of foamed cement and leave it to set.
According to a particular case of variant 1, the cement slurry may be first combined with
the aqueous foam to form a foamed mixture. Then this foamed mixture is combined with the
slurry of calcium aluminate cement using a mixer, to obtain a slurry of foamed cement
according to the invention. This slurry of foamed cement is cast and left until it sets. The
mixer used to combine the foamed mixture and the slurry of calcium aluminate cement is
preferably a static mixer.
Advantageously, the process according to the invention does not require an autoclave
step, or a curing step, or a step of thermal treatment, for example thermal treatment at 60-
80°C in order to obtain a mineral foam according to the invention.
Mineral foams according to the invention
The present invention then relates to a mineral foam obtainable according to the
process of the invention.
The mineral foam according to the invention can have a density of 100 to 600 kg/m 3.
Preferably, the mineral foam according to the invention has a density of 100 to 550
kg /m3, more preferably from 150 to 450 kg /m3, most preferably from 150 to 300 kg /m3. It is
to be noted that the density of the slurry of foamed cement (humid density) is different to the
density of the mineral foam (density of the hardened material).
The invention provides the advantage that the mineral foam according to the invention
is very lightweight, and in particular has a very low density.
The invention provides another advantage in that the mineral foam according to the
invention has excellent stability properties. In particular, it is possible to obtain a foam which
does not slump or only very slightly when the foam is poured from a height of at least one
metre for a section of 30 cm2, and for which the distribution of the density in the material
varies by at most 11%, preferably by at most 5%, more preferably by at most 2%.
The invention provides another advantage in that the mineral foam according to the
invention has excellent thermal properties, and in particular very low thermal conductivity.
Thermal conductivity (also called lambda (λ )) is a physical value characterizing the behaviour
of materials during the transfer of heat by conduction. Thermal conductivity represents the
quantity of heat transferred per unit of surface and per unit of time submitted to a gradient of
temperature. In the international system of units, thermal conductivity is expressed in watts
per metre Kelvin, (W-m -K ) . Typical or conventional concretes have thermal conductivity
values measured at 23°C and 50 % relative humidity of 1.3 to 2.1 . The thermal conductivity
of the mineral foam according to the invention is from 0.05 to 0.5 W/m.K, preferably from
0.08 to 0.3 W/m.K, more preferably from 0.08 to 0.2 W/m.K, most preferably from 0.08 to
0.18 W/m.K.
The invention provides another advantage in that the mineral foam according to the
invention has good mechanical properties, and in particular good compressive strength
compared to known mineral foams. The compressive strength of the mineral foam according
to the invention is from 0.1 to 10 MPa, preferably from 0.1 to 8 MPa, more preferably from
0.2 to 4 MPa.
 Variant 1 of the mineral foam according to the invention
According to a first variant, the mineral foam according to the invention may be
produced from a slurry of foamed cement comprising at least, in % by mass relative to the
mass of slurry of foamed cement:
- from 20 to 70 % of cement;
- from 1 to 5 % of calcium sulphate;
- from 0.5 to 10 % of calcium aluminate cement;
- from 0.05 to 3 % of a water reducer, a plasticizer or a superplasticizer;
- from 0.001 to 0.5 % of a retarder;
- from 0.1 to 5 % of a foaming agent;
- from 15 to 40 % of water;
the calcium aluminate cement/calcium sulphate ratio, expressed in mass percentage
being from 0.5 to 2.5;
the calcium sulphate/cement ratio, expressed in mass percentage being from 0.03 a
0.09.
The suitable cement for the slurry of foamed cement required to produce the mineral
foam according to the invention is preferably the cements described according to the
European NF EN 197-1 Standard of February 2001 or mixtures thereof. The preferred
cement, used according to the invention is the Portland CEM I cement, by itself or mixed with
other cements, for example those described according to the European NF EN 197-1
Standard of February 2001 .
Preferably, the slurry of foamed cement used to produce the mineral foam according to
the invention comprises 30 to 55% of cement, preferably 30 to 5 1 % , in % by mass relative to
the mass of slurry of foamed cement.
The slurry of foamed cement used to produce the mineral foam according to the
invention may comprise calcium sulphate. Calcium sulphate used according to the present
invention includes gypsum (calcium sulphate dihydrate, CaS0 4 .2H 20), hemi-hydrate
(CaS0 4 .1/2H 20), anhydrite (anhydrous calcium sulphate, CaS0 4) or a mixture thereof. The
gypsum and anhydrite exist in the natural state. Calcium sulphate produced as a by-product
of certain industrial processes may also be used.
The suitable calcium aluminate cement for the slurry of foamed cement used to
produce the mineral foam according to the invention is generally a cement comprising a
C4A 3$ , CA, C12A7, C3A or CnA 7CaF 2 mineralogical phase or mixtures thereof, for example
Fondu ® cements, sulfoaluminous cements, calcium aluminate cements conforming with the
NF EN 14647 Standard of December 2006, the cement obtained from the clinker described
in patent application W O 2006/018569 or mixtures thereof. The suitable calcium aluminate
cement for the slurry of foamed cement used to produce the mineral foam according to the
invention may be in a crystallised form or in an amorphous form.
The preferred calcium aluminate cement according to the invention is the Fondu ®
cement.
Preferably, the slurry of foamed cement used to produce the mineral foam according to
the invention comprises 0.5 to 7% of calcium aluminate cement, preferably 1 to 5 % , in % by
mass relative to the mass of slurry of foamed cement.
Preferably, the calcium aluminate cement/calcium sulphate ratio, expressed in mass
percentage, determined for the slurry of foamed cement to produce the mineral foam
according to the invention is from 0.6 to 2.2, more preferably from 0.8 to 2 .
Preferably, the calcium sulphate/cement ratio, expressed in mass percentage,
determined for the slurry of foamed cement to produce the mineral foam according to the
invention is from 0.04 to 0.08, more preferably from 0.05 to 0.07.
The slurry of foamed cement used to produce the mineral foam according to the
invention comprises a water reducer, a plasticizer or a superplasticizer. A water reducer
makes it possible to reduce the amount of mixing water for a given workability by typically
10-15%. By way of example of water reducers, mention may be made of lignosulphonates,
hydroxycarboxylic acids, carbohydrates, and other specific organic compounds, for example
glycerol, polyvinyl alcohol, sodium alumino-methyl-siliconate, sulfanilic acid and casein as
described in the Concrete Admixtures Handbook, Properties Science and Technology, V.S.
Ramachandran, Noyes Publications, 1984.
Superplasticizers belong to a new class of water reducers and are capable of reducing
water contents of mixing water, for a given workability, by approximately 30% by mass. By
way of example of a superplasticizer, the PCP superplasticizers without an anti-foaming
agent may be noted. The term "PCP" or "polyoxy polycarboxylate" is to be understood
according to the present invention as a copolymer of acrylic acids or methacrylic acids and
their esters of polyoxy ethylene (POE). It is also possible to mention the dispersing agents
with differed efficiency.
Preferably, the slurry of foamed cement used to produce the mineral foam according to
the invention comprises 0.05 to 1 % , more preferably 0.05 to 0.5 % of a water reducer, a
plasticizer or a superplasticizer, percentage expressed by mass relative to the mass of slurry
of foamed cement.
When the water reducer, the plasticizer or the superplasticizer is used in solution, the
quantity is given as active material in the solution.
According to a variant of the invention, the slurry of foamed cement used to produce
the mineral foam according to the invention does not comprise an anti-foaming agent, or any
agent having the property of destabilizing an air/liquid emulsion. Certain commercial
superplasticizers may contain anti-foaming agents and consequently these superplasticizers
are not suitable for the slurry of foamed cement used to produce the mineral foam according
to the invention.
The slurry of foamed cement used to produce the mineral foam according to the
invention comprises a retarder. The retarder corresponds to the definition of the retarder
mentioned in the European NF EN 934-2 Standard of September 2002.
The retarder used according to the invention may be selected from:
- sugars and derivative products, in particular, saccharose, glucose, sugar reducers (for
example, lactose or maltose), cellobiose, gallactose or derivative products, for example,
glucolactone;
- carboxylic acids or salts thereof, in particular gluconic acid, gluconate, tartric acid,
citric acid, gallic acid, glucoheptonic acid, saccharic acid or salicylic acid. The associated
salts comprise, for example, ammonium salt, alkali metal salt (for example sodium salt or
potassium salt), alkali earth metal salt (for example calcium salt or magnesium salt).
However, other salts may also be used;
- phosphonic acids and salts thereof, in particular aminotri(methylenephosphonic) acid,
pentasodic salt of aminotri(methylenephosphonic) acid, hexamethylene-diamine-
tetra(methylene-phosphonic) acid, diethylene-triamine-penta(methylene-phosphonic acid and
its sodium salt);
- phosphates and their derivatives;
- zinc salts, in particular zinc oxide, zinc borate and soluble zinc salts (nitrate, chloride);
- borates, in particular boric acid, zinc borate and boron salts;
- mixtures of these compounds.
Preferably, the retarder is a carboxylic acid or a salt of carboxylic acid. According to an
embodiment of the invention, the retarder is a citric acid or a salt thereof.
According to an embodiment of the invention, the retarder used in the slurry of foamed
cement according to the invention is a mixture of carboxylic acid and phosphonic acid or a
mixture of salts thereof.
Preferably, the slurry of foamed cement used to produce the mineral foam according to
the invention comprises 0.005 to 0.2 % of retarder, more preferably 0.01 to 0.1 % , in % by
mass relative to the mass of slurry of foamed cement.
The slurry of foamed cement used to produce the mineral foam according to the
invention comprises a foaming agent. The foaming agent is generally a compound which
modifies the superficial tension between two surfaces, in particular which lowers the
superficial tension at the interface between a liquid and a gas, between a liquid and a solid or
between two liquids. This compound is also called a surfactant.
 The foaming agent used according to the invention may be selected from ionic, non-
ionic, amphiphilic or amphoteric foaming agents and used alone or in mixtures.
By way of ionic surfactants, the following non-limiting examples may be mentioned:
alkylethersulfonates, hydroxyalkylethersulfonat.es, alphaolefinesulfonat.es, the
alkylbenzenesulfonat.es, alkylester sulfonates, alkylethersulfates, hydroxyalkylethersulfat.es,
alphaolefinesulfates, alkylbenzenesulfates, alkylamide sulfates, as well as their alkoxylated
derivatives (in particular ethoxylated derivatives (EO) and/or propoxylated derivatives (PO)),
or mixtures thereof.
By way of ionic surfactants, the following non-limiting examples may also be
mentioned: the saturated or insaturated fatty acid salts and/or their alkoxylated derivatives, in
particular (EO) and/or (PO) (for example lauric acid, palmitic acid or stearic acid),
alkylglycerol sulfonates, sulfonated polycarboxylic acids, paraffin sulfonates, N-akyl N-
alkyltaurates, alkylphosphates, alkylsuccinamates, alkylsulfosuccinates, monoesters or
diesters of sulfosuccinates, sulfates of alkylglucosides, for example those in acid or lactone
form and derivatives of I 17-hydroxyoctadecenic acid.
By way of non-ionic surfactants, the following non-limiting examples may be mentioned:
ethoxylated fatty acids, alkoxylated alkylphenols (in particular (EO) and/or (PO)), aliphatic
alcohols, more particularly in C8-C22, products resulting from the condensation of ethylene
oxide or propylene oxide with propylene glycol or ethylene glycol, products resulting from the
condensation of ethylene oxide or propylene oxide with ethylene diamine, amides of
alkoxylated fatty acids (in particular (EO) and/or (PO)), alkoxylated amines (in particular (EO)
and/or (PO)), alkoxylated amidoamines (in particular (EO) and/or (PO)), amine oxides,
alkoxylated terpenic hydrocarbons (in particular (EO) and/or (PO)), alkylpolyglucosides,
polymers or amphiphilic oligomers, ethoxylated alcohols, esters of sorbitan or esters of
oxyethylated sorbitan.
By way of amphoteric surfactants, the following non-limiting examples may be
mentioned: betaines, derivatives of imidazoline, polypeptides or lipoaminoacides. More
particularly, suitable betaines according to the invention may be selected from
cocamidopropyl betaine, dodecylic betaine, hexadecylic betaine and octadecylic betaine.
According to a particular embodiment of the invention, the non-ionic foaming agent may
be associated to at least one anionic foaming agent.
By way of amphiphilic surfactants, the following non-limiting examples may be
mentioned: polymers, oligomers or copolymers which are at least miscible in the aqueous
phase.
The amphiphilic polymers or oligomers may have a statistic distribution or a multi-block
distribution.
 The amphiphilic polymers or oligomers used according to the invention are selected
from block polymers comprising at least one hydrophilic block and at least one hydrophobic
block, the hydrophilic block being obtained from at least one non-ionic and/or anionic
monomer.
By way of example, the following amphiphilic polymers or oligomers may be
mentioned: polysaccharides having hydrophobic groups, in particular alkyl groups,
polyethylene glycol and its derivatives.
By way of example, the following amphiphilic polymers or oligomers may also be
mentioned: three-block polyhydroxystearate polymers - polyethylene glycol -
polyhydroxystearate or hydrophobic polyacrylamides.
Non-ionic amphiphilic polymers, and more particularly alkoxylated polymers (in
particular (EO) and/or (PO)), are more preferably selected from polymers of which at least
one part (at least 50 % by weight) is miscible in water.
By way of examples of this type of polymer, the following polymers may be mentioned
among others: three-block polyethylene glycol / polypropylene glycol / polyethylene glycol
polymer.
Preferably, the foaming agent used according to the invention is a protein, in particular
a protein of animal origin, more particularly keratin.
Preferably, the foaming agent used according to the invention is a protein with a
molecular weight of 1000 to 50 000 Daltons.
The preferred surfactants used according to the invention are the non-ionic and the
anionic surfactants.
Preferably, the foaming agent is used according to the invention at a concentration of
0.15 to 1 % , more preferably from 0.20 to 0.85 % , by mass of foaming agent relative to the
mass of slurry of foamed cement. Even more preferably, the slurry of foamed cement
comprises at least 0.1 % of foaming agent relative to the mass of slurry of foamed cement.
Most preferably, the slurry of foamed cement comprises at least 0.3 % of foaming agent
relative to the mass of slurry of foamed cement.
According to an embodiment of the invention, the slurry of foamed cement used to
produce the mineral foam according to the invention may further comprise mineral particles.
Preferably, the slurry of foamed cement used to produce the mineral foam according to
the invention may comprise 15 to 50 % of mineral particles, more preferably from 15 to 40 % ,
most preferably from 20 to 35%, the percentages being expressed by mass relative to the
mass of slurry of foamed cement.
The suitable mineral particles for the slurry of foamed cement used to produce the
mineral foam according to the invention are selected from calcium carbonate, silica, ground
glass, solid or hollow glass beads, glass granules, expanded glass powders, silica aerogels,
silica fume, slags, ground sedimentary siliceous sands, fly ash or pozzolanic materials or
mixtures thereof.
The mineral particles used according to the invention may be pozzolanic materials (for
example as defined in the European NF EN 197-1 Standard of February 2001 , paragraph
5.2.3), silica fume (for example, as defined in the European NF EN 197-1 Standard of
February 2001 , paragraph 5.2.7), slags (for example, as defined in the European NF EN
197-1 Standard of February 2001 , paragraph 5.2.2), material containing calcium carbonate,
for example limestone (for example, as defined in the European NF EN 197-1 Standard
paragraph 5.2.6), siliceous additions (for example, as defined in the "Concrete" NF P 18-509
Standard), fly ash (for example, as described in the European NF EN 197-1 Standard of
February 2001 , paragraph 5.2.4) or mixtures thereof.
Fly ash is generally pulverulent particles comprised in fume from thermal power plants
which are fed with coal. Fly ash is generally recovered by electrostatic or mechanical
precipitation.
The chemical composition of a fly ash mainly depends on the chemical composition of
the unburned carbon and on the process used in the thermal power plant where it came
from. Its mineralogical composition also depends on the same factors. The fly ash used
according to the invention may have a siliceous or calcic nature.
Slags are generally obtained by rapid cooling of molten slag resulting from melting of
iron ore in a blast furnace.
The slags used according to the present invention may be selected from granulated
blast-furnace slags according to the EN 197-1 Standard of February 2001 , paragraph 5.2.2.
Silica fume used according to the present invention may be a material obtained by
the reduction of very pure quality quartz by the coal in electric arc furnaces used for the
production of silicon and alloys of ferrosilicon. Silica fume is generally formed of spherical
particles comprising at least 85% by mass of amorphous silica.
Preferably, the silica fume used according to the present invention may be selected
from silica fume according to the European NF EN 197-1 Standard of February 2001 ,
paragraph 5.2.7.
The pozzolanic materials used according to the present invention may be natural
siliceous and/or silico-aluminous materials or a combination thereof. Among the pozzolanic
materials, natural pozzolans can be mentioned, which are generally materials of volcanic
origin or sedimentary rocks, and natural calcined pozzolans, which are materials of volcanic
origin, clays, shale or thermally-activated sedimentary rocks.
Preferably, the pozzolanic materials used according to the present invention may be
selected from the pozzolanic materials according to the European NF EN 197-1 Standard of
February 2001 paragraph 5.2.3.
 Preferably, the mineral particles used according to the invention may be limestone
powders and/or slags and/or fly ash and/or silica fume. Preferably, the mineral particles used
according to the invention are limestone powders and/or slags.
Other suitable mineral particles for the slurry of foamed cement used to produce the
mineral foam according to the invention are calcareous, siliceous or silico-calcareous
powders or mixtures thereof.
The suitable mineral particles for the slurry of foamed cement used to produce the
mineral foam according to the invention may come partially or in totality from the cement
when it is a blended cement.
Preferably, the average size of the suitable mineral particles for the slurry of foamed
cement used to produce the mineral foam according to the invention is from 0.1 to 500 µη ,
for example from 0.1 to 250 µη . The D50 of the mineral particles is preferably from 0.1 to 150
µηι , more preferably from 0.1 to 100 µηι .

According to an embodiment of the mineral foam according to the invention, the slurry
of foamed cement used to produce the mineral foam according to the invention may further
comprise a thickening agent.
The expression « thickening agent » , is generally to be understood according to the
present invention as any compound making it possible to maintain the heterogeneous
physical phases in equilibrium or facilitate this equilibrium.
The suitable thickening agents according to the invention are preferably gums,
cellulose or its derivatives, for example cellulose ethers or carboxy methyl cellulose, starch or
its derivatives, gelatine, agar, carrageenans or bentonite clays.
The suitable gums according to the invention, used as a thickening agent are
preferably selected from Acacia, Tragacanth, Carob, Dextran, Diutan, Gellan, Guar,
Scleroglucane, Xanthan, Welan gums. The expression « gum » , is generally to be
understood according to the invention as vegetable exudates or extracellular secretions with
a microbiological origin.
Preferably, the slurry of foamed cement used to produce the mineral foam of variant 1
according to the invention does not comprise lightweight aggregates as described in the
European NF EN 206-1 Standard of April 2004, for example, perlite. It does not either
comprise lightweight charges, for example polystyrene beads.
Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 20 to 35 % of water, % by mass relative to the mass of foamed
cement slurry.
Other additives may also be used in the slurry of foamed cement used to produce the
mineral foam according to the invention, for example coloured pigments, hydrophobic agents
or de-polluting agents (for example zeolites or titanium dioxide).
 Variant 2 of the mineral foam according to the invention
According to a second variant of the invention, the mineral foam according to the
invention may be produced from a slurry of foamed cement comprising at least, in % by
mass relative to the mass of the slurry of foamed cement
from 30 to 75 % of cement;
from 10 to 70 % of fine mineral particles with a D50 less than or equal to 5 µη ;
from 0 to 15 % of ultrafine mineral particles with a D50 less than or equal to 1 µ η ;
- from 0.05 to 3 % of a water reducer, a plasticizer or a superplasticizer;
- from 0.0001 to 1 % of a retarder;
from 0 to 0.1 % of a thickening agent;
de 0.01 to 5 % of a foaming agent;
from 0 to 0.5 % of alkaline sulphates;
from 0 to 1 % of an accelerator;
- from 10 to 70 % of water;
the fine mineral particles/cement ratio, expressed in mass percentage being comprised from
0.27 to 0.6;
the ultrafine mineral particles/fine mineral particles ratio, expressed in mass percentage
being comprised from 0 to 0.5.
The suitable cement for the slurry of foamed cement used to produce the mineral
foam according to the invention is preferably the cements described according to the
European NF EN 197-1 Standard of February 2001 or mixtures thereof. The preferred and
suitable cement according to the invention is the Portland CEM I cement, by itself or mixed
with other cements, for example those described according to the European NF EN 197-1
Standard of February 2001 . The CEM III cement is also suitable.
Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 35 to 60% of cement, more preferably 40 to 60 % .
The suitable fine mineral particles with a D50 less than or equal to 5 µη according to
the invention may come from one or more materials selected from fly ash, pozzolans (natural
and artificial), limestone powders, siliceous powders, lime, calcium sulphate (in particular
gypsum in the anhydrous or hemi hydrate forms) and slags.
The D50, also noted as Dv 50, corresponds to the 50 th percentile of the size
distribution of the particles, by volume; that is, 50 % of the particles have a size that is less
than or equal to D50 and 50 % of the particles have a size that is greater than D50.
The D50 of the fine particles according to the invention is less than or equal to 5 µη ,
preferably comprised from 1 to 4 µη , more preferably comprised from 1.5 to 3 µη .
 Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 15 to 60 % of fine mineral particles, more preferably 15 to 40 % ,
% by mass relative to the mass of foamed cement slurry.
Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 0 to 8 % of ultrafine mineral particles, preferably 2 to 6 % , % by
mass relative to the mass of foamed cement slurry.
The suitable ultrafine mineral particles having a D50 less than 1 µ η used according to
the invention may come from one or more materials selected from limestone powders,
precipitated calcium carbonates, natural and artificial pozzolans, pumice stones, ground fly
ash, crushed material of a hydrated or carbonated silica hydraulic binder and mixtures or co-
grindings thereof in the dry form. The term « crushed material of a hydrated silica hydraulic
binder » denotes, in particular the products described in the FR 2708592 document.
The D50 of the ultrafine mineral particles used according to the invention is less than
or equal to 1 µη , preferably comprised from 10 to 500 nm, more preferably comprised from
50 to 200 nm.
Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 0.001 to 0.5 % or a retarder, % by mass relative to the mass of
foamed cement slurry. The description provided herein above for the selection of the retarder
applies to this variant of the mineral foam according to the invention.
Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 0.001 to 0.01 % of a thickening agent, % by mass relative to the
mass of foamed cement slurry. The description provided herein above for the selection of the
thickening agent applies to this variant of the mineral foam according to the invention.
Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 0.03 to 1 % of a foaming agent, % by mass relative to the mass of
foamed cement slurry. The description provided herein above for the selection of the foaming
agent applies to this variant of the mineral foam according to the invention.
Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 0.05 to 0.8 % of an accelerator, % by mass relative to the mass of
foamed cement slurry.
The suitable accelerator according to the invention may come from one or more salts
selected from:
calcium salts, potassium salts and sodium salts wherein the anion may be nitrate,
nitrite, chloride, formiate, thiocyanate, sulphate, bromide, carbonate or mixtures
thereof;
alkali silicates and aluminates, for example sodium silicate, potassium silicate,
sodium aluminate, potassium aluminate or mixtures thereof;
 aluminium salts, for example aluminium sulphate, aluminium nitrate, aluminium
chloride, aluminium hydroxide or mixtures thereof;
or mixtures thereof.
Preferably, the slurry of foamed cement used to produce the mineral foam according
to the invention comprises 15 to 40 % of water, % by mass relative to the mass of foamed
cement slurry.
The description provided herein above for the selection of the water reducer, the
plasticizer or the superplasticizer applies to this variant of the mineral foam according to the
invention.
Other additives may also be used in the slurry of foamed cement used to produce the
mineral foam according to the invention, for example coloured pigments, hydrophobic agents
or de-polluting agents (for example zeolites or titanium dioxide).
Variant 3 of the mineral foam according to the invention
According to a third variant of the invention, the mineral foam according to the invention
may be produced from a slurry of foamed cement comprising at least, in % by mass relative
to the mass of foamed cement slurry
from 30 to 75 % of cement obtained from clinker comprising at least one
mineralogical C4A 3$ phase;
- from 0.05 to 3 % of a water reducer, a plasticizer or a superplasticizer;
from 0 to 0.1 % of a thickening agent;
from 0.01 to 5 % of a foaming agent;
- from 0.00001 to 0.01 % of lithium salt;
- from 10 to 70 % of water.

The slurry of foamed cement used to produce the mineral foam according to the invention
may comprise calcium sulphate.
Calcium sulphate used according to the present invention includes gypsum (calcium
sulphate dihydrate, CaS0 4 .2H 20), hemi-hydrate (CaS0 4 .1/2H 20), anhydrite (anhydrous
calcium sulphate, CaS0 4) or a mixture thereof. The gypsum and anhydrite exist in the natural
state. Calcium sulphate produced as a by-product of certain industrial processes may also be
used.
The slurry of foamed cement used to produce the mineral foam according to the invention
may comprise a lithium salt selected from lithium carbonate, lithium hydroxide, lithium
chloride, lithium nitrate, lithium sulphate, lithium fluoride and lithium citrate.
The slurry of foamed cement used to produce the mineral foam according to the invention
comprises a cement obtained from clinker comprising at least one mineralogical
C4A3$ phase. It may be a cement produced from the clinker described in patent application
WO 2006/018569 or cement obtained from clinker comprising at least one
C4A3$ mineralogical phase, and optionally one C2S , C3S , C 2A 7, C3A , Ca 5(Si04) 2S0 4 phase
or CnA7CaF 2 mineralogical phase or mixtures thereof.
The description provided herein above for the selection of the water reducer, the
plasticizer or the superplasticizer, the thickening agent and the foaming agent applies to this
variant of the mineral foam according to the invention.
Other additives may also be used in the slurry of foamed cement used to produce the
mineral foam according to the invention, for example coloured pigments, hydrophobic agents
or de-polluting agents (for example zeolites or titanium dioxide).
Use:
The mineral foam according to the invention may be a concrete, which is pre-cast on
the jobsite, a ready-mix concrete or a concrete produced at a production plant of pre-cast
elements. Preferably, the mineral foam according to the invention is a ready-mix concrete.
The mineral foam according to the invention may also be directly prepared on the
jobsite by installing a foaming system on the jobsite.
The invention also relates to the use of the mineral foam according to the invention as
construction material.
The mineral foam according to the invention may be used to cast walls during a jobsite.
The mineral foam according to the invention may be used for mortar beds. The mortar
bed is a coating layer making it possible to coat service ducts on a structural floor before
laying a heating floor and before casting a screed. The use of the mineral foam according to
the invention as a layer of mortar bed makes it possible to coat service ducts in one single
step and thermally insulate the heating floor of the slab. This process according to the
invention makes it possible to eliminate the step of laying the insulating layer added between
the mortar bed and the heating floor.
The invention also relates to the use of the mineral foam according to the invention as
insulating material.

Advantageously, the mineral foam according to the invention makes it possible in

certain cases to replace glass wool, mineral wool or polystyrene insulating material.
Advantageously, the mineral foam according to the invention may be used to fill in
empty or hollow spaces in a building, a wall, a partition wall, a floor or a ceiling. In this case,
it is used as a filling compound.
Advantageously, the mineral foam according to the invention may be used as facade
lining to insulate a building from the outside. In this case, the mineral foam according to the
invention may be coated by a finishing compound.
The invention also relates to a system comprising the mineral foam according to the
invention. The mineral foam may be present in the system, for example as insulating
material. The system according to the invention is a system capable of resisting to transfers
of air and to thermohydric transfers, which is to say that this element has controlled
permeability to transfers of air or water in the vapour or liquid form.
The system according to the invention, which resists to transfers of air and to
thermohydric transfers in the construction field, comprises at least a framework. This
framework may be secondary or primary. This framework may be of metal, cement fibres,
wood, composite material or a synthetic material. This framework may be a metal structure, a
stud or a rail.
The system according to the invention may be used to produce a lining, an insulation
system or a partition wall, for example a separation partition wall, a distribution partition wall
or an inner partition.
The mineral foam according to the invention may be cast vertically between two walls,
for example between two concrete walls or two plaster boards, to obtain a system.
The invention also relates to an element of construction comprising the mineral foam
according to the invention.

EXAMPLES
Laser granulometry method
In this specification, including the accompanying claims, particle size distributions and

particle sizes are as measured using a Malvern MS2000 laser granulometer. Measurement is
effected in ethanol. The light source consists of a red He-Ne laser (632 nm) and a blue diode
(466 nm). The optical model is that of Mie and the calculation matrix is of the polydisperse
type.
The apparatus is checked before each working session by means of a standard sample
(Sibelco C10 silica) for which the particle size distribution is known.
Measurements are performed with the following parameters: pump speed 2300rpm and
stirrer speed 800rpm. The sample is introduced in order to establish an obscuration between
10 and 20%. Measurement is effected after stabilisation of the obscuration. Ultrasound at
80% is first applied for 1 minute to ensure the de-agglomeration of the sample. After about
30s (for possible air bubbles to clear), a measurement is carried out for 15 s (15000 analysed
images). Without emptying the cell, measurement is repeated at least twice to verify the
stability of the result and elimination of possible bubbles.
All values given in the description and the specified ranges correspond to average
values obtained with ultrasound.
Particle sizes greater than 200 µηι are generally determined by sieving.
 Materials:
The cement is a Portland CEM I 52.5 R cement from the Lafarge cement plant of Le
Havre (Batch number: LHY-4062).
The calcium sulphate is ground anhydrous calcium sulphate from the plant of Le Pin
worked by Etex.
The calcium aluminate cement is a Fondu ® cement from the Pyrallis company.
The plasticizer is a mixture comprising a polycarboxylate polyoxide (PCP) from the
Chryso company under the brand name of Chrysolab EPB 530-017; it is based on Premia
180 which does not comprise an anti-foaming agent.
The retarder is a pure anhydrous citric acid from the Verre Labo Mula company.
The foaming agent is the Propump 26, an animal protein from the Propump company:
the molecular weight of Propump 26 is 6000 Daltons.
The mineral particles are calcium carbonate supplied by OMYA under the following
brand names:
Betocarb HP Entrains wherein the D50 is 7.8 µη , and having a maximum particle
size of 200 µηι (Batch number: ADD-0549);
Durcal 1 wherein the D50 is 2.5 µη , and having a maximum particle size of 20 µη

(Batch number:ADD-0613);
Durcal 1 wherein the D50 is 3.5 µη , and having a maximum particle size of 20 µη

(Batch number:ADD-00662);
- Socal 3 1 wherein the D50 is 90 nm, (Batch number: MCC-265).
The thickening agent is either a biopolymer from the CP Kelco company
commercialised under the brand name of Kelco-Crete 200.
The accelerator is calcium nitrite from Chryso commercialised under the brand name of
SET 02.
The LiC03 is lithium carbonate from the Aldrich company.
Water: tap water.

Materials:
The Rayneri mixers:
- A mixer: model R 602 EV (2003) supplied by the Rayneri company. The mixer is
composed of a chassis on which vessels are positioned (capacity: 10 to 60 litres). The 60-
litre blade was used with a paddle type of blade adapted to the volume of the vessel. This
paddle is entrained by an electric motor operating on 380 Volts at a variable speed. The
blade exerts a rotation movement around itself, accompanied by a planetary movement
around the axis of the vessel.
- A Turbotest mixer (MEXP-101 , model: Turbotest 33/300, Serial N°: 123861 ) supplied
by the Rayneri company. It was a mixer with a vertical axis.
In the following examples, 9 mineral foams according to the invention were produced.

They are numbered 1 to 9 . Each cement slurry and each aqueous foam carries the same
number as the obtained mineral foam.

1/ Production of mineral foams 1 to 5 according to the invention comprising

cement and calcium aluminate cement (Variant 1):

Production of slurries of cement and calcium aluminate cement :

Tables 1 and 2 herein below give the chemical compositions of the different cement
slurries and of the aqueous foam which were used.
The slurry of Portland cement and the slurry of calcium aluminate cement were
produced using the Rayneri R 602 EV mixer.

Table 1:

The quantities in Table 1 are given in % by mass relative to the total mass of each slurry.
 Table 2 :

the quantity of Propump 26 is the quantity of active material for the commercial product.
( ' the quantities of Table 2 are given in % by mass relative to the total mass of aqueous foam (water + foaming
agent)

Production of a slurry of foamed cement according to the invention:

The production of slurries of foamed cement (1 to 5) was carried out in a continuous
manner. The cement slurries, obtained beforehand, were each poured separately into a
buffer vessel whilst being stirred in a Rayneri Turbotest mixer (MEXP-101) comprising a
deflocculating blade (the speed of the blade could vary from 1000 rpm to 400 rpm depending
on the volume of the slurry). The slurries were pumped for the flow rates given in Table 3
using a Moineau volumetric pump:
- Seepex™ MD 003-1 2 helical rotor pump - commission N°: 245928 for the slurry of
calcium aluminate cement; and
Seepex™ BN025-1 2 helical rotor pump - commission N° 244921 for the cement
slurry;
Table 3 herein below presents the flow values of each ingredient (cement slurry and
aqueous foam) used to produce the slurries of foamed cement according to the invention .

Table 3 :

the flow rates are given in g/ min

 Production of the aqueous foam:
The aqueous solution of the foaming agent was co-introduced through the foamer
with the pressurized air (within a range of 1 to 6 bars) using a T junction. The
aqueous foam was generated in a continuous manner at the flow rate given in Table
3;
(bed of SB30 glass beads with a diameter comprised from 0.8 to 1.4 mm, packed in a
tube: length 100 mm and diameter 12 mm).
The slurry of cement and the slurry of calcium aluminate cement were combined to
obtain a third slurry of cement. Then, the third slurry of cement was combined with the
aqueous foam already circulating in the circuit of the process. The slurry of foamed cement
according to the invention was thus generated. The static mixer was the Kenics® type of
mixer, supplied by Robbins & Myers Inc., with 16 elements, interior diameter: 20 mm, length:
260 mm.
Five slurries of foamed cement were obtained, numbered from 1 to 5 ; their
compositions are given in Table 4 herein below.

Table 4 :

the quantity of foaming agent is the quantity of active material for the commercial product.
( ' the quantities of Table 4 are given in % by mass relative to the total mass of the slurry of foamed cement

Production of mineral foams according to the invention:

The slurries of foamed cement 1 to 5 were then either poured into columns of Plexiglas:
1 or 2 metres in height and 10 cm diameter, or into 10X10X10 cm-side cubes of polystyrene.
The cubes were demoulded after 24h00 and kept for 28 days at 100% of relative humidity
and 20°C. The columns were demoulded after 24h00, kept for 7 days at 100% of relative
humidity and 20°C, then dried at 45°C until their mass remained constant.

Stability of the mineral foams according to the invention:

After drying at 45°C and obtaining a constant mass, sections in the columns were cut at
2 cm from the bottom and 2 cm from the top of the column. The sections were 10
centimetres high. The sections were carefully measured and the densities were evaluated.
The density obtained at the bottom of the column and the difference of density between the
top and the bottom of the column are recorded in Table 5 .

Table 5 :

n.d. not determined

Thermal conductivity of the mineral foams according to the invention:

Thermal conductivity was measured using a thermal conductivity measuring device: the
CT-metre (Resistance 5 Ω , probe wire 50 mm). The samples were dried in a drying oven at
45°C until their mass remained constant. The sample was then cut into two equal pieces
using a saw. The measurement probe was placed between the two flat sides of these two
half samples (the sawed sides). Heat was transmitted from the source towards the
thermocouple through the material surrounding the probe. The rise in temperature of the
thermocouple was measured over time and the thermal conductivity of the sample was
calculated.
The values are given in Table 6 .
Table 6 :
Thermal conductivity

1 2 3 4 5

Thermal conductivity (W/ m.K) 0.1 14 0.188 0.159 0.166 0.164

 Mechanical compressive strengths of the mineral foams:
The mechanical strength was tested on the 10X1 0X1 0 cm cubes. Each sample
was submitted to mechanical compressive stress until failure of the sample using a Zwick™
press (PRES-001 8-1 997/03). The maximum force exerted on the surface of the sample was
measured in this manner. A compressive strength was deduced . The measurements were
carried out in a temperature-stabilised environment (23°C) and 50% relative humidity. The
results obtained are given in Table 7 . Each value is an average of three measurements.

Table 7 :

21 Production of mineral foams 6 to 8 according to the invention comprising

cement and fine particles (Variant 2)

Production of slurries of Portland cement:

Tables 8 and 9 herein below present the chemical compositions of the slurries of
cement (Table 8) and the aqueous foam (Table 9) which were used .

Table 8 :

The quantities in Table 8 are given in % by mass relative to the total mass of each slurry.
 Table 9 :

( ' the quantity of Propump 26 is the quantity of active material of the commercial product.
( The quantities in Table 9 are given in % by mass relative to the total mass of aqueous foam (water + foaming
agent)

Production of a slurry of foamed cement according to the invention:

The production of slurries of foamed cement (6 to 8) was carried out in a continuous
manner. The cement slurries, obtained beforehand, were poured into a buffer vessel whilst
being stirred in a Rayneri Turbotest mixer (MEXP-101) comprising a deflocculating blade
(the speed of the blade could vary from 1000 rpm to 400 rpm depending on the volume of the
slurry). The slurries were pumped for the flow rates given in Table 10 using a
Moineau volumetric pump (Seepex™ MD 003-12 helical rotor pump - commission N°:
245928).
Table 10 herein below presents the flow rates for each ingredient (slurry of cement and
aqueous foam) used to produce the slurries of foamed cement according to the invention.

Table 10:

Production of the aqueous foam:

The aqueous solution of the foaming agent was co-introduced through the foamer
with the pressurized air (within a range of 1 to 6 bars) using a T junction. The
aqueous foam was generated in a continuous manner at the flow rate given in Table
10;
(bed of SB30 glass beads with a diameter comprised from 0.8 to 1.4 mm, packed in
a tube: length 100 mm and diameter 12 mm).
 The slurry of cement and the aqueous foam already circulating in the circuit of the
process were combined. The slurries of foamed cement according to the invention were then
generated. The static mixer was the Kenics ® type of mixer supplied by Robbins & Myers Inc.,
with 16 elements, interior diameter: 20 mm, length: 260 mm.

Table 11: Formulation of the slurries of foamed cements

the quantity of foaming agent is the quantity of active material for the commercial product.
( ' the quantities of Table 11 are given in % by mass relative to the total mass of foamed cement slurry

Production of mineral foams according to the invention:

The slurries of foamed cement 6 to 8 were then either poured into columns of Plexiglas:
1, 2 or 3 metres in height and 20 cm diameter, or into 10X10X10 cm-side cubes of
polystyrene. The cubes were demoulded after 24h00 and kept for 28 days at 100% of
relative humidity and 20°C. The columns were demoulded after 24h00, kept for 7 days at
100% of relative humidity and 20°C, then dried at 45°C until their mass remained constant.

Stability of the mineral foams 6 to 8 according to the invention:

After drying at 45°C and obtaining a constant mass, sections in the columns were cut at
2 cm from the bottom and 2 cm from the top of the column. The sections were 10
centimetres high. The sections were carefully measured and the densities were evaluated.
The density obtained at the bottom of the column and the difference of density between the
top and the bottom of the column are recorded in Table 12.
 Table 12:

Thermal conductivity of the mineral foams 6 to 8 according to the invention:

Thermal conductivity was measured using a thermal conductivity measuring device: the
CT-metre (Resistance 5 Ω , probe wire 50 mm). The samples were dried in a drying oven at
45°C until their mass remained constant. The sample was then cut into two equal pieces
using a saw. The measurement probe was placed between the two flat sides of these two
half samples (the sawed sides). Heat was transmitted from the source towards the
thermocouple through the material surrounding the probe. The rise in temperature of the
thermocouple was measured over time and the thermal conductivity of the sample was
calculated. The values are given in Table 13.

Table 13:

Mechanical compressive strengths of the mineral foams 6 to 8:

The mechanical strength was tested on the 10X10X10 cm cubes. Each sample
was submitted to mechanical compressive stress until failure of the sample using a Zwick™
press (PRES-001 8-1 997/03). The maximum force exerted on the surface of the sample was
measured in this manner. A compressive strength was deduced. The measurements were
carried out in a temperature-stabilised environment (23°C) and 50% relative humidity. The
results obtained are given in Table 14. Each value is an average of three measurements.
 Tableau 14 :

n.d. not determined

3/ Production of a mineral foam 9 according to the invention comprising cement

(Variant 3)
The mineral foam 9 was produced according to the same process as the foams 6 to 8 .
This mineral foam 9 was produced from cement obtained from the clinker described in patent
application WO 2006/01 8569 (cement A).

The chemical composition of the cement slurry was the following:

The quantities are given in % by mass relative to the total mass of each slurry.

The chemical composition of the aqueous foam was the following:

' the quantity of foaming agent is the quantity of active material for the commercial product.
( 4 the quantities of the table are given in % by mass relative to the total mass of the aqueous foam (water +
foaming agent)

Flow rates of the slurry of cement and the aqueous foam

9

Cement slurry (g/min) 401 6

Aqueous foam (g/min) 259
Average D50 of the bubbles of the aqueous foam ( µ ι) 250
Air flow rate (L/min) 5.3
Formulation of the slurry of foamed cement

the quantity of foaming agent is the quantity of active material for the commercial product
the quantities are given in % by mass relative to the total mass of the slurry of foamed cement

The obtained thermal conductivity value was 0.1 17 W/m.K. The obtained compressive
strength wasl .88 Pa.
 CLAIMS
1. A process for production of a mineral foam comprising the following steps:
(i) separately prepare one or more slurries of cement, and an aqueous foam for which
the D50 of the bubbles is less than or equal to 400 µη ;
(ii) homogenize this or these slurries of cement with the aqueous foam to obtain a
slurry of foamed cement;
(iii) cast the slurry of foamed cement and leave it to set.
2 . The process for production of a mineral foam according to claim 1 wherein step (i)
comprises the preparation of two slurries of cement, one of which is a slurry of
calcium aluminate cement.
3 . The process for production of a mineral foam according to claim 1 or claim 2 wherein
step (ii) comprises the introduction of the slurry or slurries of cement and the aqueous
foam into a static mixer to obtain a slurry of foamed cement.
4 . The mineral foam obtainable according to the process of any one of claims 1 to 3 .
5 . The mineral foam obtainable according to claim 4 having a density of 100 to 600
kg/m 3.
6 . A mineral foam according to claim 4 or claim 5 produced from a slurry of foamed
cement comprising at least, in % by mass relative to the mass of the slurry of foamed
cement:
- from 20 to 70 % of cement;
- from 1 to 5 % of calcium sulphate;
- from 0.5 to 10 % of calcium aluminate cement;
- from 0.05 to 3 % of a water reducer, a plasticizer or a superplasticizer;
- from 0.001 to 0.5 % of a retarder;
- from 0.1 to 5 % of a foaming agent;
- from 15 to 40 % of water;
the calcium aluminate cement/ calcium sulphate ratio, expressed in mass percentage
being from 0.5 to 2.5;
the calcium sulphate/cement ratio, expressed in mass percentage being from 0.03 to
0.09.
7 . The mineral foam according to claim 6 wherein the slurry of foamed cement
comprises 15 to 50 % of mineral particles.
8 . The mineral foam according to claim 7 wherein the mineral particles are selected from
calcium carbonate, silica, ground glass, solid or hollow glass beads, glass granules,
expanded glass powders, silica aerogels, silica fume, slags, ground sedimentary
siliceous sands, fly ash or pozzolanic materials or mixtures thereof.
9 . The mineral foam according to claim 6 or claim 7 wherein the calcium aluminate
cement/calcium sulphate ratio is from 0.6 to 2.2.
10. The mineral foam according to claim 6 or claim 7 wherein the calcium
sulphate/cement ratio is from 0.04 to 0.08.
11. The mineral foam according to claim 4 or claim 5 produced from a slurry of foamed
cement comprising at least, in % by mass relative to the mass of the slurry of foamed
cement
- from 30 to 75 % of cement;
- from 10 to 70 % of fine mineral particles with a D50 less than or equal to 5 µη ;
- from 0 to 15 % of ultrafine mineral particles with a D50 less than or equal to 1 µ η ;
- from 0.05 to 3 % of a water reducer, a plasticizer or a superplasticizer;
- from 0.0001 to 1 % of a retarder;
- from 0 to 0.1 % of a thickening agent;
- from 0.01 to 5 % of a foaming agent;
- from 0 to 0.5 % of alkaline sulphates;
- from 0 to 1 % of an accelerator;
- from 10 to 70 % of water;
the fine mineral particles/cement ratio, expressed in mass percentage, being
comprised from 0.27 to 0.6;
the ultrafine mineral particles/fine particles ratio, expressed in mass percentage,
being comprised from 0 to 0.5.
12. The mineral foam according to claim 4 or claim 5 produced from a slurry of foamed
cement comprising at least, in % by mass relative to the mass of foamed cement
slurry
- from 30 to 75 % of cement obtained from clinker comprising at least one
mineralogical C4A 3$ phase;
- from 0.05 to 3 % of a water reducer, a plasticizer or a superplasticizer;
- from 0 to 0.1 % of a thickening agent;
- from 0.01 to 5 % of a foaming agent;
- from 0.00001 to 0.01 % of lithium salt;
- from 10 to 70 % of water.
13. A use of the mineral foam according to any one of claims 4 to 12 as construction
material.
14. A use of the mineral foam according to any one of claims 4 to 12 as insulating
material.
15 . A n element of construction comprising a mineral foam according to any one of claims
4 to 12.
A . CLASSIFICATION O F SUBJECT MATTER
INV. C04B28/02 C04B28/04 C04B38/10
ADD.

According to International Patent Classification (IPC) o r t o both national classification and IPC

B . FIELDS SEARCHED
Minimum documentation searched (classification system followed by classification symbols)
C04B

Documentation searched other than minimum documentation to the extent that such documents are included in the fields searched

Electronic data base consulted during the international search (name of data base and, where practicable, search terms used)

EPO-Internal , INSPEC, WPI Data

C . DOCUMENTS CONSIDERED TO B E RELEVANT

Category* Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim No.

A WO 2006/018569A2 ( LAFARGE SA [FR] ; 1-15

GARTNER ELLIS [FR] ; LI GUANSHU [FR] )
23 February 2006 (2006-02-23)
c i ted i n the appl i cati on
c l aims 1-16; exampl e s 1-6

A W0 2010/070214 Al ( LAFARGE SA [FR] ; 1-15

WALENTA GUENTHER [FR] ; C0MPARET CEDRIC
[FR] ; M0RIN VI ) 24 June 2010 (2010-06-24)
c l aims 1-15 ; exampl e exempl e s

A EP 2 105 419 Al ( LAFARGE SA [FR] ) 1-15

30 September 2009 (2009-09-30)
c l aims 1-11 ; exampl e s 1 , 2

A F R 2 941 450 Al ( LAFARGE SA [FR] ) 1-15

30 July 2010 (2010-07-30)
c l aims 1-14; exampl e exempl e s

□ Further documents are listed in the continuation of Box C . See patent family annex.

* Special categories of cited documents :

"T" later document published after the international filing date o r priority
date and not in conflict with the application but cited to understand
"A" document defining the general state of the art which is not considered
the principle o r theory underlying the invention
to be of particular relevance
"E" earlier application o r patent but published o n o r after the international
"X" document of particular relevance; the claimed invention cannot be
filing date considered novel o r cannot b e considered to involve a n inventive
"L" documentwhich may throw doubts o n priority claim(s) orwhich is step when the document is taken alone
cited to establish the publication date of another citation o r other
"Y" document of particular relevance; the claimed invention cannot be
special reason (as specified)
considered to involve a n inventive step when the document is
"O" document referring to a n oral disclosure, use, exhibition o r other combined with one o r more other such documents, such combination
means being obvious to a person skilled in the art
"P" document published prior to the international filing date but later than
the priority date claimed "&" document member of the same patent family

Date of the actual completion of the international search Date of mailing of the international search report

22 Apri l 2013 02/05/2013

Name and mailing address of the ISA/ Authorized officer
European Patent Office, P.B. 5818 Patentlaan 2
N L - 2280 HV Rijswijk
Tel. (+31-70) 340-2040,
Fax: (+31-70) 340-3016 Burtan , M
 Patent document Publication Patent family Publication
cited in search report date member(s) date

WO 2006018569 A2 23-02-2006 AT 434592 T 15-07 2009

BR PI0513507 A 06- 05 2008
CA 2574532 Al 23- 02 2006
CN 101023043 A 22- 08 2007
CN 102745918 A 24- 10 2012
CN 102765892 A 07- 1 1 2012
EG 25879 A 23- 09 2012
EP 1781579 A2 09- 05 2007
ES 2327254 T3 27-10 2009
FR 2873366 Al 27-01 2006
P 5123661 B2 23-01 2013
P 2008506628 A 06-03 2008
KR 20070043854 A 25- 04 2007
MA 28744 Bl 02- 07 2007
PT 1781579 E 12-10 2009
RU 2360874 C2 10- 07 2009
SI 1781579 Tl 31-10 2009
US 2007266903 Al 22- 1 1 2007
US 2010132590 Al 03- 06 2010
W0 2006018569 A2 23- 02 2006
ZA 200701333 A 30-07 2008

W0 2010070214 Al 24-06-2010 CA 2747347 Al 24-06-2010

CN 102256911 A 23-11-2011
EP 2379466 Al 26-10-2011
US 2011259247 Al 27-10-2011
W0 2010070214 Al 24-06-2010

EP 2105419 Al 30-09-2009 CA 2712437 Al 01-10-2009

CN 101952216 A 19-01-2011
EP 2105419 Al 30-09-2009
EP 2285749 Al 23-02-2011
JP 2011515323 A 19-05-2011
KR 20100132498 A 17-12-2010
RU 2010144065 A 10-05-2012
US 2011041736 Al 24-02-2011
W0 2009118652 Al 01-10-2009

FR 2941450 Al 30-07-2010 NONE