Ettringite binder for dense mortar, comprising calcium sulphates and a mineral compound of calcium aluminates

• US 20060118006A1
• Filed: 04/24/2003
• Published: 06/08/2006
• Est. Priority Date: 04/24/2002
• Status: Active Grant

• Current Assignee: Kerneos
• Original Assignee: Kerneos
• Inventors: Touzo, Bruno, Amathieu, Loris
• Granted Patent: US 7,208,040 B2
• Time in Patent Office: Days
• US Class Current: 106/611
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 24/14 Peptides; Proteins; Derivatives thereof
• CPC Class Codes: C04B 24/223 Sulfonated melamine-formaldehyde condensation products
• CPC Class Codes: C04B 24/246 containing polyether side chains
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/2647 containing polyether side chains
• CPC Class Codes: C04B 28/065 Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
• CPC Class Codes: C04B 40/0608 Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: C04B 7/323 Calcium aluminosulfate cements, e.g. cements hydrating into ettringite

Abstract

The invention relates to an ettringite binder for dense mortar, comprising calcium sulphates and a calcium aluminate mineral compound, the calcium aluminate mineral compound comprising calcium C and aluminum A oxides, soluble and combined in one or more crystallized and/or amorphous mineralogical phases, in such proportions that: the useful C/A molar ratio of the calcium aluminate mineral compound ranges from 1.2 to 2.7; the sum in weight of the useful (C+A) phases accounts for at least 30% of the total weight of the mineral compound.

Claims

1. An ettringite binder for dense mortar comprising calcium sulphates and a calcium aluminate mineral compound, characterized in that such a calcium aluminate mineral compound comprises calcium C and aluminium A oxides, soluble and combined into one or more crystallized and/or amorphous mineralogical phases, in such proportions that:

the useful C/A molar ratio of the calcium aluminate mineral compound ranges from 1.2 to 2.7;

the sum in weight of the useful (C+A) phases accounts for at least 30% of the total weight of the mineral compound.

2. An ettringite binder for dense mortar according to claim 1, characterized in that the calcium aluminate mineral compound /calcium sulphate weight ratio ranges from 0.5 to 4, preferably from 1.5 to 3.

3. An ettringite binder for dense mortar according to claim 2, characterized in that the calcium sulphate/aluminium A oxide molar ratio in the ettringite binder ranges from 0.5 to 2.

4. An ettringite binder for dense mortar according to claim 1, characterized in that the useful C/A molar ratio of the calcium aluminate mineral compound ranges from 1.3 to 2.5, preferably from 1.6 to 2.

5. An ettringite binder for dense mortar according to claim 3 [[or 4]], characterized in that the calcium sulphate/aluminium A oxide molar ratio in the ettringite binder ranges from 0.6 to 1.8, preferably from 0.8 to 1.7.

6. An ettringite binder for dense mortar according to claim 1, characterized in that such a mortar comprising the ettringite binder has, when mixed with water, a water/solids weight ratio lower than 0.5.

7. An ettringite binder for dense mortar according to claim 1, characterized in that the mortar does not comprise any Portland cement or hydraulic lime, or comprises Portland cement and/or hydraulic lime at content lower than 3.5% in weight based on the total weight of the dry mortar.

8. An ettringite binder for dense mortar according to claim 1, characterized in that the sum in weight of the useful (C+A) phases accounts for at least 50% in weight of the total weight of the calcium aluminate mineral compound.

9. An ettringite binder for dense mortar according t claim 1, characterized in that the calcium aluminate mineral compound is obtained through baking in an oven at a temperature higher than 1100°

C., under the form of one or more molten or sintered clinkers able to contain crystallized phases or amorphous phases.

10. An ettringite binder for dense mortar according to claim 1, characterized in that the calcium aluminate mineral compound is under the form of a crystallized mineralogical phase selected amongst CA, C12A7, C3A, C4A3$, or under the form of an amorphous phase, or under the form of a mixture of at least one of said crystallized mineralogical phases and one amorphous phase.

11. An ettringite binder for dense mortar according to claim 10, characterized in that the calcium aluminate mineral compound comprises at least 30% in weight of C12A7, preferably at least 50% in weight of C12A7, more preferably from 50% to 85% in weight of C12A7 based on the total weight of the mineral compound.

12. An ettringite binder for dense mortar according to claim 1 any of claims 1 to 11, characterized in that the calcium aluminate mineral compound comprises at least one crystallized mineralogical phase selected amongst C2A(1−

x)Fx, C2S, C2AS, C3S and mixtures thereof, where x is an integer belonging to ]0;

1 ].

13. An ettringite binder for dense mortar according to claim 1, characterized in that the calcium aluminate mineral compound is ground and has a Blaine surface area higher than or equal to 1500 cm²/g.

14. An ettringite binder for dense mortar according to claim 13, characterized in that the calcium aluminate mineral compound is ground and has a Blaine surface area ranging from 2000 cm²/g to 5000 cm²/g.

15. An ettringite binder for dense mortar according to claim 1, characterized in that the calcium sulphate is derived from a compound selected amongst anhydrites, semi-hydrates, gypsum and mixtures thereof.

16. A dry mortar characterized in that it comprises:

an ettringite binder as defined in claim 1;

from 15% to 75% in weight based on the total weight of the dry mortar,

chalk fillers or siliceous sands;

from 25% to 85% in weight based on the total weight of the dry mortar,

lime and/or Portland cement;

from 0% to 3.5% in weight based on the total weight of the dry mortar,

redispersible powder polymers;

from 0% to 8% in weight based on the total weight of the dry mortar, and/or solid-liquid dispersion polymers;

from 0% to 20% in weight based on the total weight of the dry mortar, and

rheological additives and/or setting regulating additives.

17. A dry mortar according to claim 16, characterized in that it comprises:

an ettringite binder as defined in claims 1 to 15;

from 20% to 50% in weight based on the total weight of the dry mortar,

chalk fillers or siliceous sands;

from 50% to 80% in weight based on the total weight of the dry mortar,

lime and/or Portland cement;

from 0% to 0.5% in weight based on the total weight of the dry mortar,

redispersible powder polymers;

from 0% to 5% in weight based on the weight total of the dry mortar, and/or solid-liquid dispersion polymers;

from 0% to 15% in weight based on the total weight of the dry mortar,

rheological additives and/or setting regulating additives.

18. A dry mortar according to claim 16, characterized in that the Theological additives account for from 0.1% to 0.5% of the total weight of the dry mortar, and the setting regulating additives account for 0.1% to 0.5% of the total weight of the dry mortar.

19. A wet mortar obtained through mixing a dry mortar such as defined in claim 16, with water in such an amount that the water/solids weight ratio is lower than 0.5.

20. (canceled)

21. (canceled)

22. (canceled)