Blended fly ash pozzolans

• US 20060201395A1
• Filed: 03/08/2005
• Published: 09/14/2006
• Est. Priority Date: 03/08/2005
• Status: Abandoned Application

• Current Assignee: ASH Grove Cement Company (CRH PLC)
• Original Assignee: ASH Grove Cement Company (CRH PLC)
• Inventors: Barger, Gregory S., Wiedenhoft, Charles T.
• Application Number:
  US11/076,096
• Publication Number:
  US 20060201395A1
• Time in Patent Office: Days
• US Class Current: 106/705
• CPC Class Codes: C04B 14/365 Gypsum synthetic gypsum C04B18/0445, C04B18/064
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2111/2015 Sulfate resistance
• CPC Class Codes: C04B 2111/2023 Resistance against alkali-aggregate reaction
• 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

Novel premium blended pozzolans for use with hydraulic cement are created by intergrinding an ASTM Class F or Class C coal fly ash and a source of calcium sulfate, such as gypsum, so that the resultant mixture has a fineness of at least 90% passing through a 45 micron sieve. The novel mixture meets the requirements of ASTM C 618. Alternately, a novel concrete composition can be formed using the blended pozzolan with a hydraulic cement, aggregate and water so as to produce a concrete having improved strength, ASR mitigation, improved sulfate resistance and lowered permeability. The novel pozzolans not only reduce production costs by decreasing fuel and raw material consumption per ton of cement, but they also use by-product waste materials from another industry to create a premium product for the construction industry.

Claims

1. A blended pozzolan for use with hydraulic cement and comprising:

a) fly ash meeting the requirements of ASTM C 618 Class C or F;

b) a calcium sulfate component; and

c) the fly ash and the calcium sulfate component being interground to a fineness of at least 90% passing through a 45 micron sieve and meeting the requirements of ASTM C 618 for coal fly ash.

2. The blended pozzolan set forth claim 1 including silica fume interground with the fly ash and calcium sulfate component.

3. The blended pozzolan set forth in claim 1 wherein the calcium sulfate component is gypsum.

4. The blended pozzolan set forth in claim 1 including an air entraining agent.

5. The blended pozzolan set forth in claim 1 wherein there is an approximate proportion of 93% fly ash and 7% calcium sulfate component.

6. The blended pozzolan set forth in claim 1 wherein the proportion of fly ash to calcium sulfate component is selected to optimize sulfate resistance, volume stability, alkali silica reaction mitigation and compressive strength.

7. A concrete composition comprising:

a) blended pozzolan formed by intergrinding fly ash with a calcium sulfate component to a fineness of at least 90% passing through a 45 micron sieve;

b) hydraulic cement meeting the requirements of ASTM C 150, C 595 or C 1157;

c) aggregate meeting the requirements of ASTM C 33;

d) water meeting the requirements of ASTM C 04; and

e) the above components producing a concrete having the uniquely improved strength, alkali-silica-reactivity mitigation, improved sulfate resistance and lowered permeability.

8. The concrete composition, set forth in claim 7 wherein the blended fly ash is a Class F fly ash.

9. The concrete composition, set forth in claim 7 wherein the calcium sulfate component is gypsum.

10. A blended pozzolan for use with hydraulic cement and comprising:

a) fly ash meeting the requirement of ASTM C 618 Class C or F;

b) a calcium sulfate component; and

c) the fly ash and calcium sulfate component being interground in a proportion selected to optimize sulfate resistance, volume stability, alkali silica reaction mitigation and compressive strength, the intergrinding being to a fineness of at least 90% passing through a 45 micron sieve, the blended pozzolan meeting the requirement of ASTM C 618 for coal fly ash.