Method for producing materials from recycled glass and cement compositions

• US 20050045069A1
• Filed: 08/24/2004
• Published: 03/03/2005
• Est. Priority Date: 08/25/2003
• Status: Active Grant

• Current Assignee: IceStone LLC
• Original Assignee: IceStone LLC
• Inventors: McCarthy, Timothy, McCarthy, Carol A., Rangarajan, Sriram
• Granted Patent: US 7,700,017 B2
• Time in Patent Office: Days
• US Class Current: 106/716
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/34 Metals , e.g. ferro-silicon
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2103/54 Pigments; Dyes
• CPC Class Codes: C04B 2103/603 Agents for controlling alkali-aggregate reactions
• CPC Class Codes: C04B 24/18 Lignin sulfonic acid or derivatives thereof, e.g. sulfite lye
• CPC Class Codes: C04B 24/22 Condensation or polymerisation products thereof
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0067 making use of vibrations
• CPC Class Codes: C04B 40/024 : Steam hardening, e.g. in an autoclave
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 264/915 : From inorganic material containing articles or products, e.g. hydro-set, cement, plaster, wire, cable

Abstract

A method of producing material from recycled glass comprising: preparing a mixture of glass in a cementitious matrix, and an alkali-silica reaction suppressant; providing a mold of the material and coating said mold with a release agent; casting said mixture into said mold; curing said mold; and removing the material from said mold. The recycled glass and concrete compositions are: 25-79% by weight glass; 8-35% by weight cement and up to 22% by weight of an alkali-silica reaction suppressant.

Claims

1. A composition comprised of:

25-79% by weight glass;

8-35% by weight hydraulic cement; and

up to 22% by weight of an alkali-silica reaction suppressant.

2. The composition according to claim 1, wherein said alkali-silica reaction suppressant is selected from the group consisting of metakaolin, fly ash, silica fume and blast furnace slag.

3. The composition according to claim 1, further comprising a dispersant present in an amount up to 3% by weight

4. The composition according to claim 3, wherein said dispersant is selected from the group consisting of polycarboxylate based dispersants, naphthalene based dispersants, melamine based dispersants and lignosulphate based dispersants.

5. The composition according to claim 1, wherein said glass and said cement are present in ratio of from 5/7 to 10/1.

6. The composition according to claim 1, wherein said glass is in a crushed or ground form.

7. The composition according to claim 6, wherein the particle sizes of said glass are between 1 μ

m to 25 mm.

8. The composition according to claim 1, further comprising a pigment component present in an amount up to 15% by weight.

9. The composition according to claim 1, further comprising a fiber component present in an amount up to 5% by weight.

10. The composition according to claim 1, further comprising at least one material from the group consisting of stone chips, shell chips, mother of pearl chips, metal chips, air-entraining agents, anti-foaming agents, and viscosity modifying agents.

11. A method of producing material from recycled glass comprising:

(a) preparing a mixture of glass in a cementitious matrix, and an alkali-silica reaction suppressant;

(b) providing a mold of the material and coating said mold with a release agent;

(c) casting said mixture into said mold;

(d) curing said mold; and

(e) removing the material from said mold.

12. The method according to claim 11 wherein said cementitious matrix is comprised of a mixture of calcium silicates and aluminates and a dispersant and said alkali-silica reaction suppressant is metakaolin.

13. The method according to claim 11, wherein said glass is in a crushed or ground form and has a particle size in the range of 1 μ

m to 25 mm.

14. The method according to claim 11, wherein said curing is in a controlled environmental chamber.

15. The method according to claim 11, wherein said mixture is cured to a solid state under humidity ranges from 70% to 100% RH and at temperatures between 50°

F. to 185°

F.

16. The method according to claim 11, further comprising vibrating said mold after casting to distribute said mixture uniformly within said mold and remove entrapped air.

17. The method according to claim 11, wherein said mold is in the form of a flat panel.

18. The method according to claim 17, wherein said panel formed is rectangular and has dimensions ranging up to 60″

×

120″ and

over 0.5″

in thickness.

19. The method according to claim 11, said mold is in the form of 3-D objects.

20. A product made from a composition comprised of:

25-79% by weight glass;

8-35% by weight hydraulic cement; and

up to 22% by weight of an alkali-silica reaction suppressant.