Pozzolan modified portland cement compositions and admixtures therefor

• US 20030233962A1
• Filed: 06/21/2002
• Published: 12/25/2003
• Est. Priority Date: 06/21/2002
• Status: Abandoned Application

• Current Assignee: Jonathan E. Dongell
• Original Assignee: Jonathan E. Dongell
• Inventors: Dongell, Jonathan E.
• Application Number:
  US10/177,918
• Publication Number:
  US 20030233962A1
• Time in Patent Office: Days
• US Class Current: 106/709
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 2111/24 Sea water resistance
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0039 Premixtures of ingredients
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A pozzolan admixture composition suitable for use in portland cement mixtures and mix designs that, when combined with; portland cement, sand and/or aggregate, and water, are used to prepare cementitious products. The admixture contains ultra-fine fly ash, calcined kaolin, fused silica, and cellulose ether derivative. A pozzolan-modified portland cement composition containing the present invention'"'"'s composition inter-ground or inter-blended with a portland cement. The pozzolan-modified portland cement contains portland cement, ultra-fine fly ash, calcined kaolin, fused silica, and a cellulose ether derivative. An admixture, additive, or addition, based on the present invention'"'"'s composition, inter-ground or inter-blended into portland cement to create such pozzolan-modified portland cements. An admixture, additive, or addition, based on the present invention, that is subsequently added or mixed into a read-mix or wet mixture of portland cement, sand and/or aggregate, and water, containing ultra-fine fly ash, calcined kaolin, fused silica, and cellulose ether derivative.

Claims

12. A composition of matter comprising water and a quantity of dry materials including from about 65% to about 88% (w/w) of portland cement;

from about 5% to about 27% (w/w) of calcined kaolin;

from about 3% to about 27% (w/w) of ultra-fine fly ash;

from about 1% to about 15% (w/w) of fused silica; and

from about 0.05% to about 1.0% of a cellulose ether derivative, said weight percentages (w/w) being taken relative to the total weight of said quantity of dry materials.

1. An admixture for subsequent addition to portland cement to create a pozzolan modified portland cementitious material, said pozzolan modified portland cementitious material having from about 5% to about 35% (w/w) of said admixture blended therein, said admixture comprising:

from about 5% to about 47% (w/w) of fused silica;

from about 17.5% to about 67% (w/w) of calcined kaolin;

from about 10% to about 57% (w/w) of ultra-fine fly ash;

from about 0.5% to about 2% (w/w) of a cellulose ether derivative.

2. An admixture matter according to claim 1 wherein said calcined kaolin is ground to a fineness of at least 200 mesh (75 micron) with a maximum of about 5% retaining;

said fused silica is ground to a fineness of at least 325 (45 micron) mesh with a maximum of about 5% retaining, and said ultra-fine fly ash having a fineness that is of at least 10 micron or finer.

3. An admixture according to claim 1 containing from about 33% to about 67% (w/w) of said ultra-fine fly ash;

and from about 33% to about 67% (w/w) of said calcined kaolin.

4. An admixture according to claim 1 containing from about 33% to about 67% (w/w) of said ultra-fine fly ash;

and from about 33% to about 67% (w/w) of said fused silica.

5. An admixture according to claim 1 containing from about 17.5% to about 67% (w/w) of said ultra-fine fly ash;

from about 20% to about 67% (w/w) of said calcined kaolin; and

from about 7% to about 22.5% (w/w) of said fused silica.

6. An admixture according to claim 1 containing from about 12.5% to about 67% (w/w) of said ultra-fine fly ash;

from about 17.5% to about 67% (w/w) of said calcined kaolin;

from about 7% to about 22.5% (w/w) of said fused silica; and

from about 0.1% to about 2.0% (w/w) of said cellulose ether derivative.

7. A composition of matter comprising water, sand and/or aggregate, and a pozzolan modified portland cement containing portland cement and from about 5% to about 35% (w/w) of the admixture of claim 1.

8. A composition comprising the admixture of claim 1, adapted for use in general construction.

9. A composition comprising the admixture of claim 1, adapted for use in the construction of structures to be exposed to water.

10. A composition comprising the admixture of claim 1, adapted for the construction of pre-cast members.

11. A composition comprising the admixture of claim 1, adapted for the construction of pre-fabricated units for the construction of buildings.

13. A composition of matter according to claim 7 containing a functional equivalent to fused silica consisting of an amorphous silica such as micro-silica or silica fume in place of the fused silica having a fineness of at least 325 mesh (45 micron), and having no more than 5% retained.

14. A composition of matter according to claim 7 containing a functional equivalent to calcined kaolin consisting of a calcined natural pozzolan of a fineness at least 200 mesh (75 micron), having no more than 5% retained.

15. A composition of matter according to claim 12 containing from about 65% to about 88% (w/w) of said portland cement;

from about 5% to about 27% (w/w) of calcined kaolin;

from about 3% to about 27% (w/w) of ultra-fine fly ash;

from about 1% to about 15% (w/w) of fused silica.

16. A composition of matter according to claim 12 containing from about 65% to about 88% (w/w) of said portland cement;

from about 3% to about 27% (w/w) of ultra-fine fly ash;

from about 1% to about 15% (w/w) of fused silica, and from about 0.05% to about 1.0% of a cellulose ether derivative.

17. A composition of matter according to claim 12 containing from about 60% to about 85% (w/w) of said portland cement;

from about 5% to about 27% (w/w) of calcined kaolin;

from about 3% to about 27% (w/w) of ultra-fine fly ash; and

from about 0.05% to about 1.0% (w/w) of a cellulose ether derivative.

18. A composition of matter according to claim 12 containing a functional equivalent to fused silica consisting of an amorphous silica, such as micro-silica or silica fume, in place of the fused silica having a fineness of at least 325 mesh (45 micron) and no more than 5% retained.

19. A composition of matter according to claim 12 containing a functional equivalent to calcined kaolin consisting of a calcined natural pozzolan having a fineness at least 200 mesh (75 micron) and no more than 5% retained.

20. A composition of matter according to claim 12 wherein said calcined kaolin is ground to a fineness of at least 200 mesh (75 micron) with a maximum of about 5% retaining;

and said fused silica is of a fineness of at least 325 (45 micron) mesh with a maximum of about 5% retaining, and a ultra-fine fly ash having a fineness of at least 10 micron.

21. A composition of matter comprising sand, and/or aggregate, and the composition of claim 12.

22. A composition of matter according to claim 12 in which said dry materials are mixed with water, and sand and/or aggregate, during job mixing.

23. A composition of matter according to claim 18 in which said dry materials are mixed with water, and sand and/or aggregate, during job mixing.

24. A composition comprising the composition of claim 12, adapted for use in general construction.

25. A composition comprising the composition of claim 12, adapted for use in the construction of structures to be exposed to water.

26. A composition comprising the composition of claim 12, adapted for the construction of pre-cast members.

27. A composition of matter according to claim 12 in which said water is mixed with said dry materials during job mixing.

28. A composition of matter according to claim 18 in which said water is mixed with said dry materials during job mixing.

29. A composition of matter according to claim 19 in which said water is mixed with said dry materials during job mixing.

26-1. A composition comprising the composition of claim 12, adapted for the construction of pre-fabricated units for the construction of buildings.

30. A pozzolan-modified blended or inter-ground portland cement containing comprising from about 60% to about 88% (w/w) of portland cement thoroughly blended or inter-ground with a single composition addition, or with multiple component additions, or with individual component additions, that are the collective equivalent of the present invention, comprising;

from about 65% to about 88% (w/w) of portland cement, from about 5% to about 27% (w/w) of calcined kaolin, from about 3% to about 27% (w/w) of ultra-fine fly ash, from about 1% to about 15% (w/w) of fused silica, and from about 0.05% to about 1.0% of a cellulose ether derivative.

31. A composition of matter according to claim 30 additionally comprising water, sand and/or aggregate.

32. A composition comprising the pozzolanic portland cement of claim 30, adapted for use in general construction.

33. A composition comprising the pozzolanic portland cement of claim 30, adapted for use in the construction of structures to be exposed to water.

34. A composition comprising the pozzolanic portland cement of claim 30, adapted for the construction of pre-cast members.

35. A composition comprising the pozzolanic portland cement of claim 30, adapted for the construction of pre-fabricated units for the construction of buildings.

36. A composition of matter according to claim 30 containing a functional equivalent to fused silica consisting of an amorphous silica, such as micro-silica or silica fume, in place of the fused silica having a fineness of at least 325 mesh (45 micron), and having no more than 5% retained.

37. A composition of matter according to claim 30 containing a functional equivalent to calcined kaolin consisting of a calcined natural pozzolan having a fineness at least 200 mesh (75 micron), and having no more than 5% retained.